CN108289721B - Surgical instrument - Google Patents

Abstract

The invention discloses a surgical instrument. The surgical instrument includes a first jaw and a second jaw, wherein at least one of the first jaw member and the second jaw member is movable relative to the other of the first jaw member and the second jaw member between an open configuration and an approximated configuration. Further, the surgical instrument includes a cutting member movable during a firing stroke to cut tissue captured between the first jaw and the second jaw, the cutting member including a cutting surface at a distal portion thereof. In addition, the surgical instrument further includes a sensing module operable to measure a characteristic of the cutting surface.

Description

Surgical instrument

Cross Reference to Related Applications

This patent application relates to the following patent application docket numbers: END7420USNP/140125 entitled "circular AND SENSOR FOR POWERED MEDICAL DEVICE", END7421USNP/140126 entitled "advanced SENSOR WITH ONE SENSOR AFFECTING A connected SENSOR 'S OUTPUT OR across present complete" END7423USNP/140128 entitled "power SENSOR WITH ONE SENSOR AFFECTING A connected SENSOR' S OUTPUT OR across present", END7424USNP/140129 entitled "power sensitive HALL MAGNET TO detected fault sensitive trigge", END7425USNP/140130 entitled "SMART CARTRIDGE WAKE OPERATION AND DATA remaining", END7425 useful/140130 entitled "MULTIPLE contact status FOR POWERED 744", END7426USNP/140131 entitled "power OF MULTIPLE status field, AND section OF" priority OF "AND filed concurrently WITH each OF these applications, AND incorporated herein by reference in their entirety.

Background

Embodiments of the present invention relate to surgical instruments and, in various instances, to surgical stapling and cutting instruments and staple cartridges therefor that are designed to staple and cut tissue.

Disclosure of Invention

In one embodiment, a surgical instrument is provided. The surgical instrument includes a first jaw; a second jaw, wherein at least one of the first jaw and the second jaw is movable relative to the other of the first jaw and the second jaw between an open configuration and an approximated configuration to capture tissue between the first jaw and the second jaw; a cutting member movable during a firing stroke to cut tissue captured between the first jaw and the second jaw in an approximated configuration, the cutting member including a cutting surface at a distal portion thereof; and a sensing module operable to measure a characteristic of the cutting surface.

In one embodiment, the sensing module includes an optical sensor defining an optical sensing region. In one embodiment, the sensing module includes a light source operable to emit light. In one embodiment, the cutting surface reflects light emitted by the light source, and wherein the optical sensor is operable to measure at least one intensity of the reflected light as the cutting surface advances through the optical sensing region.

In one embodiment, the surgical instrument further comprises a cleaning mechanism. In one embodiment, the cleaning mechanism is configured to clean the cutting surface before the cutting surface enters the optical sensing region.

In one embodiment, the second jaw comprises a staple cartridge. The nail bin comprises a bin body; and a plurality of staples deployable from the cartridge body during a firing stroke, the plurality of staples being deployable into tissue captured between the first jaw and the second jaw. In one embodiment, the sensing module includes an optical sensor housed within the cartridge body.

In one embodiment, the surgical instrument further comprises a processor; and a memory coupled to the processor to store program instructions that, when executed from the memory, cause the processor to evaluate the sharpness of the cutting surface.

In one embodiment, a surgical instrument is provided. The surgical instrument includes an anvil; a staple cartridge, wherein at least one of the anvil and the staple cartridge is movable relative to the other of the anvil and the staple cartridge between an open configuration and an approximated configuration to capture tissue between the anvil and the staple cartridge; and a cutting member comprising a cutting surface at a distal portion of the cutting member, wherein the cutting member is movable relative to the staple cartridge to cut tissue captured between the anvil and the staple cartridge in the approximated configuration; and a cut surface sharpness testing module. The cutting surface sharpness testing module includes a cutting surface sharpness testing member, wherein the cutting surface is movable along a path, wherein the cutting surface sharpness testing member is configured to interrupt the path of the cutting surface; a processor; and a memory coupled to the processor to store program instructions that, when executed from the memory, cause the processor to evaluate the sharpness of the cutting surface based on at least one measurement received by the processor, the at least one measurement being detectable when the cutting surface is in contact with the cutting surface sharpness testing member.

In one embodiment, the at least one measurement comprises a time measurement. In one embodiment, the at least one measurement comprises a force measurement. In one embodiment, the cutting surface sharpness testing module includes a load cell, and wherein the load cell is operable to measure the force measurement. In one implementation, the program instructions, when executed from the memory, cause the processor to alert a user when the force measurement exceeds a threshold.

In one embodiment, a staple cartridge comprises a cartridge body; a plurality of staples deployable from the cartridge body during a firing stroke; an elongate slot extending longitudinally along a length of the cartridge body, wherein the path of the cutting surface extends at least partially through the elongate slot, and wherein the cutting surface sharpness test member is disposed on a proximal portion of the elongate slot. In one embodiment, the cartridge body comprises a cartridge deck, and wherein the cutting surface sharpness testing member is at least partially attached to the cartridge deck.

In one embodiment, a surgical instrument is provided that includes an anvil; a staple cartridge, wherein at least one of the anvil and the staple cartridge is movable relative to the other of the anvil and the staple cartridge between an open configuration and an approximated configuration; and a cutting member comprising a cutting surface at a distal portion of the cutting member, wherein the cutting member is movable relative to the staple cartridge to cut tissue captured between the anvil and the staple cartridge; and a cutting surface sharpness testing module. The cutting surface sharpness testing module comprises a tissue thickness sensing arrangement for sensing the thickness of tissue captured between the anvil and the staple cartridge; a tissue load sensing device for sensing the resistance of tissue captured between the anvil and the staple cartridge to the cutting surface; a processor; and a memory storing program instructions that, when executed from the memory, cause the processor to: receiving at least one tissue thickness measurement of tissue captured between the anvil and the staple cartridge from a tissue thickness sensing device; receiving at least one force measurement from a tissue load sensing device, the at least one resistance measurement being detectable when a cutting surface contacts tissue captured between the anvil and the staple cartridge; and determining whether the at least one force measurement exceeds a force threshold associated with the at least one tissue thickness measurement.

In one embodiment, the program instructions, when executed from the memory, cause the processor to alert a user when at least one resistance measurement exceeds a threshold associated with the at least one tissue thickness measurement. In one embodiment, the surgical instrument further comprises a firing lockout, wherein the program instructions, when executed from the memory, cause the processor to activate the firing lockout when the at least one resistance measurement exceeds a threshold associated with the at least one tissue thickness measurement. In one embodiment, the memory stores a database comprising: a plurality of force thresholds including the force threshold; and a plurality of tissue thickness ranges, each of the plurality of tissue thickness ranges corresponding to one of the plurality of force thresholds, wherein the program instructions, when executed from the memory, cause the processor to: determining a range from the plurality of tissue thickness ranges, the range including the at least one tissue thickness measurement, and comparing the at least one force measurement to the force threshold associated with the tissue thickness range including the at least one tissue thickness measurement.

Drawings

The features and advantages of various embodiments of the present invention, as well as the methods of attaining them, will become more apparent and the embodiments of the invention themselves will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a surgical instrument having an interchangeable shaft assembly operably coupled thereto;

FIG. 2 is an exploded assembly view of the interchangeable shaft assembly and surgical instrument of FIG. 1;

FIG. 3 is another exploded assembly view showing portions of the interchangeable shaft assembly and surgical instrument of FIGS. 1 and 2;

FIG. 4 is an exploded assembly view of a portion of the surgical instrument of FIGS. 1-3;

FIG. 5 is a cross-sectional side view of a portion of the surgical instrument of FIG. 4 with the firing trigger in a fully actuated position;

FIG. 6 is another cross-sectional view of a portion of the surgical instrument of FIG. 5 with the firing trigger in an unactuated position;

FIG. 7 is an exploded assembly view of one form of an interchangeable shaft assembly;

FIG. 8 is another exploded assembly view of portions of the interchangeable shaft assembly of FIG. 7;

FIG. 9 is another exploded assembly view of portions of the interchangeable shaft assembly of FIGS. 7 and 8;

FIG. 10 is a cross-sectional view of a portion of the interchangeable shaft assembly of FIGS. 7-9;

FIG. 11 is a perspective view of a portion of the shaft assembly of FIGS. 7-10 with the switch drum omitted for clarity;

FIG. 12 is another perspective view of the interchangeable shaft assembly portion of FIG. 11 with the switch drum mounted thereon;

FIG. 13 is a perspective view of a portion of the interchangeable shaft assembly shown in FIG. 11 operably coupled to a portion of the surgical instrument of FIG. 1, showing a closure trigger of the surgical instrument in an unactuated position;

FIG. 14 is a right side elevational view of the interchangeable shaft assembly and surgical instrument of FIG. 13;

FIG. 15 is a left side elevational view of the interchangeable shaft assembly and surgical instrument of FIGS. 13 and 14;

FIG. 16 is a perspective view of a portion of the interchangeable shaft assembly shown in FIG. 11 operably coupled to a portion of the surgical instrument of FIG. 1, showing a closure trigger of the surgical instrument in an actuated position and a firing trigger thereof in an unactuated position;

FIG. 17 is a right side elevational view of the interchangeable shaft assembly and surgical instrument of FIG. 16;

FIG. 18 is a left side elevational view of the interchangeable shaft assembly and surgical instrument of FIGS. 16 and 17;

FIG. 18A is a right side elevational view of the interchangeable shaft assembly illustrated in FIG. 11 operably coupled to a portion of the surgical instrument of FIG. 1, showing a closure trigger of the surgical instrument in an actuated position and a firing trigger thereof in an actuated position;

FIG. 19 is a schematic view of a system for powering down an electrical connector of a surgical instrument handle when a shaft assembly is not coupled to the electrical connector;

FIG. 20 is an exploded view of one embodiment of an end effector of the surgical instrument of FIG. 1;

FIGS. 21A-21B are circuit diagrams of the surgical instrument of FIG. 1 spanning two sheets of paper;

fig. 22 illustrates an example of a power assembly including a usage cycle circuit configured to generate a usage cycle count for a battery pack;

FIG. 23 illustrates one embodiment of a process for sequentially powering up segmented circuits;

FIG. 24 illustrates one embodiment of a power section including a plurality of daisy-chained power converters;

FIG. 25 illustrates one embodiment of a segmented circuit configured to maximize power available for critical and/or power intensive functions;

FIG. 26 illustrates one embodiment of a power system including a plurality of daisy-chained power converters configured to be sequentially energized;

FIG. 27 illustrates one embodiment of a segmented circuit comprising a single point control segment;

FIG. 28 illustrates one embodiment of an end effector including a first sensor and a second sensor;

FIG. 29 is a logic diagram illustrating one embodiment of a method for adjusting measurements of a first sensor based on input from a second sensor of the end effector shown in FIG. 28;

FIG. 30 is a logic diagram illustrating one embodiment of a method for determining a look-up table for a first sensor based on input from a second sensor;

FIG. 31 is a logic diagram illustrating one embodiment of a method for calibrating a first sensor in response to input from a second sensor;

FIG. 32A is a logic diagram illustrating one embodiment of a method for determining and displaying the thickness of a tissue section clamped between an anvil and a staple cartridge of an end effector;

FIG. 32B is a logic diagram illustrating one embodiment of a method for determining and displaying the thickness of a tissue section clamped between an anvil and a staple cartridge of an end effector;

FIG. 33 is a graph showing an adjusted Hall effect thickness measurement compared to an unmodified Hall effect thickness measurement;

FIG. 34 illustrates one embodiment of an end effector including a first sensor and a second sensor;

FIG. 35 illustrates one embodiment of an end effector comprising a first sensor and a plurality of second sensors;

FIG. 36 is a logic diagram illustrating one embodiment of a method for adjusting measurements of a first sensor in response to a plurality of second sensors;

FIG. 37 shows one embodiment of a circuit configured to convert signals from a first sensor and a plurality of second sensors into digital signals that can be received by a processor;

FIG. 38 shows an embodiment of an end effector comprising a plurality of sensors;

FIG. 39 is a logic diagram illustrating one embodiment of a method for determining one or more tissue properties based on a plurality of sensors;

FIG. 40 illustrates one embodiment of an end effector comprising a plurality of sensors coupled to a second jaw member;

FIG. 41 illustrates one embodiment of a staple cartridge including a plurality of sensors integrally formed therein;

FIG. 42 is a logic diagram illustrating one embodiment of a method for determining one or more parameters of a tissue segment clamped within an end effector;

FIG. 43 illustrates one embodiment of an end effector comprising a plurality of redundant sensors;

FIG. 44 is a logic diagram illustrating one embodiment of a method for selecting the most reliable outputs from a plurality of redundant sensors;

FIG. 45 illustrates one embodiment of an end effector including a sensor having a particular sampling rate to limit or eliminate glitches;

FIG. 46 is a logic diagram illustrating one embodiment of a method for generating a thickness measurement of a tissue section positioned between an anvil and a staple cartridge of an end effector;

FIG. 47 illustrates one embodiment of a circular stapler;

FIGS. 48A-48D illustrate the clamping process of the circular stapler shown in FIG. 47, wherein the figures illustrate

48A shows the circular stapler in an initial position with the anvil and body in a closed configuration

48B shows the anvil moved distally to disengage the body and create a gap configured to receive a tissue section therein once the circular stapler 3400 is positioned, and 48C shows the tissue section compressed to a predetermined amount of compression between the anvil and the body; and figure 48D shows the circular stapler in a position corresponding to staple deployment;

FIG. 49 illustrates one embodiment of a circular stapler anvil and electrical connectors configured to engage therewith;

FIG. 50 illustrates one embodiment of a surgical instrument including a sensor coupled to a drive shaft of the surgical instrument;

FIG. 51 is a flow chart illustrating one embodiment of a method for determining uneven tissue loading in an end effector;

FIG. 52 illustrates an embodiment of an end effector configured to determine one or more parameters of a tissue segment during a clamping operation;

FIGS. 53A and 53B illustrate one embodiment of an end effector configured to normalize the Hall effect voltage regardless of the deck height of the staple cartridge;

FIG. 54 is a logic diagram illustrating one embodiment of a method for determining when tissue compression within an end effector (e.g., the end effector shown in FIGS. 53A-53B) has reached steady state;

FIG. 55 is a graph showing various Hall effect sensor readings;

FIG. 56 is a logic diagram illustrating one embodiment of a method for determining when tissue compression within an end effector (e.g., the end effector shown in FIGS. 53A-53B) has reached steady state;

FIG. 57 is a logic diagram illustrating one embodiment of a method for controlling an end effector to improve proper staple formation during deployment;

FIG. 58 is a logic diagram illustrating one embodiment of a method for controlling an end effector to allow fluid evacuation and provide improved staple formation;

59A-59B illustrate one embodiment of an end effector including a pressure sensor;

FIG. 60 illustrates one embodiment of an end effector including a second sensor positioned between a staple cartridge and a second jaw member;

FIG. 61 is a logic diagram illustrating one embodiment of a method for determining and displaying the thickness of a tissue segment clamped in the end effector according to FIGS. 59A-59B or 60;

FIG. 62 illustrates one embodiment of an end effector including a second plurality of sensors positioned between a staple cartridge and an elongate channel;

FIGS. 63A and 63B further illustrate the effect of a full versus partial occlusion of tissue.

FIG. 64 illustrates one embodiment of an end effector comprising a coil and oscillator circuit for measuring the gap between the anvil and the staple cartridge;

FIG. 65 shows an alternative view of the end effector. As shown, in some embodiments, external wiring may supply power to the oscillator circuit;

fig. 66 shows an example of the operation of a coil for detecting eddy currents in a target.

FIG. 67 shows a graph of measured quality factor, measured inductance, and measured resistance for coil radius as a function of coil-to-target spacing;

FIG. 68 illustrates one embodiment of an end effector including an emitter and a sensor disposed between a staple cartridge and an elongate channel;

FIG. 69 shows an embodiment of the emitter and sensor in operation;

FIG. 70 shows a surface of an embodiment of an emitter and sensor including a MEMS transducer;

FIG. 71 shows a graph of an example of a reflected signal that may be measured by the emitter and sensor of FIG. 69;

FIG. 72 shows an embodiment of an end effector configured to determine the position of a cutting member or knife;

FIG. 73 shows an example of a code strip operating with red and infrared LEDs;

FIG. 74 illustrates a partial perspective view of an end effector of a surgical instrument including a staple cartridge according to various embodiments described herein;

FIG. 75 illustrates a front view of a portion of the end effector of FIG. 74, according to various embodiments described herein;

fig. 76 illustrates a logic diagram of modules of the surgical instrument of fig. 74 in accordance with various embodiments described herein;

FIG. 77 illustrates a partial view of the cutting edge, optical sensor, and light source of the surgical instrument of FIG. 74 according to various embodiments described herein;

FIG. 78 illustrates a partial view of the cutting edge, optical sensor, and light source of the surgical instrument of FIG. 74 according to various embodiments described herein;

FIG. 79 illustrates a partial view of the cutting edge, optical sensor, and light source of the surgical instrument of FIG. 74 according to various embodiments described herein;

FIG. 80 illustrates a partial view of the cutting edge, optical sensor, and light source of the surgical instrument of FIG. 74 according to various embodiments described herein;

FIG. 81 illustrates a partial view of the cutting edge, optical sensor, and light source of the surgical instrument of FIG. 74 according to various embodiments described herein;

fig. 82 illustrates a partial view of a cutting edge between cleaning blades of the surgical instrument of fig. 74 according to various embodiments described herein;

FIG. 83 illustrates a partial view of a cutting edge between the cleaning sponges of the surgical instrument of FIG. 74, according to various embodiments described herein;

FIG. 84 illustrates a perspective view of a staple cartridge including a sharpness testing member according to various embodiments described herein;

fig. 85 illustrates a logic diagram of modules of a surgical instrument according to various embodiments described herein;

fig. 86 illustrates a logic diagram of modules of a surgical instrument according to various embodiments described herein;

FIG. 87 illustrates a logic diagram listing a method for assessing the sharpness of a cutting edge of a surgical instrument in accordance with various embodiments described herein;

FIG. 88 illustrates a graph of forces exerted by the sharpness testing member of FIG. 84 against a cutting edge of a surgical instrument at various levels of sharpness according to various embodiments described herein;

fig. 89 illustrates a flow chart listing a method for determining whether a cutting edge of a surgical instrument is sufficiently sharp to transect tissue captured by the surgical instrument in accordance with various embodiments described herein;

fig. 90 illustrates a table showing predefined tissue thicknesses and corresponding predefined threshold forces according to various embodiments described herein.

FIG. 91 shows a perspective view of a surgical instrument including a handle, shaft assembly, and end effector;

FIG. 92 illustrates a logic diagram for a common control module used with multiple motors of the surgical instrument of FIG. 91;

FIG. 93 illustrates a partial front view of the handle of the surgical instrument of FIG. 91 with the outer housing removed;

FIG. 94 illustrates a partial front view of the surgical instrument of FIG. 91 with the outer housing removed;

FIG. 95A shows a side angle view of the end effector with the anvil in the closed position showing one LED on either side of the cartridge platform;

FIG. 95B shows a three quarter view of the end effector with the anvil in the open position and one LED on either side of the cartridge deck;

FIG. 96A shows a side view of the end effector with the anvil in the closed position, and a plurality of LEDs located on either side of the cartridge platform;

FIG. 96B shows a three quarter view of the end effector with the anvil in the open position, and a plurality of LEDs located on either side of the cartridge deck;

FIG. 97A shows a side angle view of the end effector with the anvil in the closed position and a plurality of LEDs located on either side of the cartridge deck from the proximal end to the distal end of the staple cartridge; and is

Fig. 97B shows a three-quarter view of the end effector with the anvil in the open position showing a plurality of LEDs located on either side of the cartridge deck from the proximal end to the distal end of the staple cartridge.

Fig. 98A shows an embodiment in which a tissue compensator is removably attached to an anvil portion of an end effector;

FIG. 98B illustrates a detail view of a portion of the tissue compensator shown in FIG. 98A;

FIG. 99 illustrates various exemplary embodiments for detecting a distance between an anvil and an upper surface of a staple cartridge using a layer of conductive elements and conductive elements in the staple cartridge;

Figures 100A and 100B illustrate an embodiment of a tissue compensator comprising a layer of conductive elements in operation;

101A and 101B illustrate an embodiment of an end effector comprising a tissue compensator that further comprises a conductor embedded therein;

102A and 102B illustrate an embodiment of an end effector comprising a tissue compensator that further comprises a conductor embedded therein;

FIG. 103 illustrates an embodiment of a staple cartridge and a tissue compensator wherein the staple cartridge provides power to the conductive elements comprising the tissue compensator;

104A and 104B illustrate an embodiment of a staple cartridge and a tissue compensator, wherein the staple cartridge provides power to the electrically conductive elements that comprise the tissue compensator;

105A and 105B illustrate an embodiment of an end effector comprising a position sensing element and a tissue compensator;

106A and 106B illustrate an embodiment of an end effector comprising a position sensing element and a tissue compensator;

FIGS. 107A and 107B illustrate an embodiment of a staple cartridge and a tissue compensator operable to indicate the position of a cutting member or knife bar;

FIG. 108 illustrates one embodiment of an end effector comprising a magnet and a Hall effect sensor, wherein a detected magnetic field can be used to identify a staple cartridge;

FIG. 109 illustrates one embodiment of an end effector comprising a magnet and a Hall effect sensor, wherein a detected magnetic field can be used to identify a staple cartridge;

FIG. 110 shows a graph of voltage detected by a Hall effect sensor positioned in the distal tip of a staple cartridge, e.g., as shown in FIGS. 108 and 109, in response to a distance or gap between a magnet positioned in the anvil and the Hall effect sensor in the staple cartridge, e.g., as shown in FIGS. 108 and 109;

FIG. 111 illustrates one embodiment of a housing of a surgical instrument including a display;

FIG. 112 illustrates one embodiment of a staple holder including a magnet;

113A and 113B illustrate one embodiment of an end effector that includes sensors for identifying different types of staple cartridges;

FIG. 114 is a partial view of an end effector having sensor power conductors for transmitting power and data signals between connecting components of a surgical instrument according to one embodiment.

FIG. 115 is a partial view of the end effector shown in FIG. 114, illustrating sensors and/or electronic components positioned in the end effector.

Fig. 116 is a block diagram of a surgical instrument electronics subsystem including short circuit protection circuitry for sensors and/or electronic components, according to one embodiment.

Fig. 117 is a short-circuit protection circuit including a supplemental power circuit 7014 coupled to a main power circuit, according to one embodiment.

Fig. 118 is a block diagram of a surgical instrument electronics subsystem including a sample rate monitor to achieve power reduction by limiting the sample rate and/or duty cycle of a sensor component when the surgical instrument is in a non-sensing state, according to one embodiment.

Fig. 119 is a block diagram of a surgical instrument electronics subsystem including over-current/over-voltage protection circuitry for sensors and/or electronic components of a surgical instrument, according to one embodiment.

Fig. 120 is an over-current/over-voltage protection circuit for sensors and electronic components of a surgical instrument, according to one embodiment.

Fig. 121 is a block diagram of a surgical instrument electronics subsystem with reverse polarity protection circuitry for sensors and/or electronic components, according to one embodiment.

Fig. 122 is a reverse polarity protection circuit for sensors and/or electronic components of a surgical instrument, according to one embodiment.

Fig. 123 is a block diagram of a surgical instrument electronics subsystem that implements power reduction with a sleep mode monitor for sensors and/or electronics, according to one embodiment.

Fig. 124 is a block diagram of a surgical instrument electronics subsystem including a temporary power loss circuit to provide protection against intermittent power loss of sensors and/or electronic components in a modular surgical instrument.

Fig. 125 illustrates one embodiment of a temporary power loss circuit implemented as a hardware circuit.

FIG. 126A illustrates a perspective view of one embodiment of an end effector including a magnet and a Hall effect sensor in communication with a processor;

FIG. 126B illustrates a side cross-sectional view of an embodiment of an end effector including a magnet and a Hall effect sensor in communication with a processor;

FIG. 127 illustrates one embodiment of the operational dimensions associated with the operation of a Hall effect sensor;

FIG. 128A shows an exterior side view of an embodiment of a staple cartridge;

FIG. 128B shows various possible dimensions between the lower surface of the push-out ear and the top of the Hall effect sensor;

FIG. 128C shows an exterior side view of an embodiment of a staple cartridge;

FIG. 128D illustrates various possible dimensions between the lower surface of the ejection ear and the upper surface of the staple cartridge above the Hall effect sensor;

Fig. 129A further illustrates a front end cross-sectional view of the anvil 10002 and a center axis point of the anvil;

FIG. 129B is a cross-sectional view of the magnet shown in FIG. 129A;

FIGS. 130A-130E illustrate one embodiment of an end effector comprising a magnet, wherein FIG. 130A illustrates a front end cross-sectional view of the end effector, FIG. 130B illustrates a front end cross-sectional view of the anvil and magnet in situ, FIG. 130C illustrates a perspective cross-sectional view of the anvil and magnet, FIG. 130D illustrates a side cross-sectional view of the anvil and magnet, and FIG. 130E illustrates a top cross-sectional view of the anvil and magnet;

FIGS. 131A-131E illustrate another embodiment of an end effector comprising a magnet, wherein FIG. 131A illustrates a front cross-sectional view of the end effector, FIG. 131B illustrates a front cross-sectional view of the anvil and magnet in situ, FIG. 131C illustrates a perspective cross-sectional view of the anvil and magnet, FIG. 131D illustrates a side cross-sectional view of the anvil and magnet, and FIG. 131E illustrates a top cross-sectional view of the anvil and magnet;

FIG. 132 illustrates the point of contact between the anvil and the staple cartridge and/or elongate channel;

FIGS. 133A and 133B illustrate an embodiment of an end effector that is operable to make electrical connections with conductive surfaces at distal contact points;

Fig. 134A-134C illustrate one embodiment of an end effector that is operable to form electrical connections with electrically conductive surfaces, wherein fig. 134A illustrates an end effector that includes an anvil, an elongate channel, and a staple cartridge, fig. 134B illustrates an inner surface of the anvil that also includes a first electrically conductive surface positioned distal to the staple forming indentations, and fig. 134C illustrates a staple cartridge that includes a cartridge body and a first electrically conductive surface positioned such that they are in contact with a second electrically conductive surface positioned on the staple cartridge;

fig. 135A and 135B illustrate one embodiment of an end effector that is operable to form an electrical connection with an electrically conductive surface, wherein fig. 135A illustrates the end effector including an anvil, an elongate channel, and a staple cartridge, and fig. 135B is a close-up view of the staple cartridge showing a first electrically conductive surface positioned such that it is in contact with a second electrically conductive surface;

fig. 136A and 136B illustrate one embodiment of an end effector that is operable to form an electrical connection with an electrically conductive surface, wherein fig. 136A illustrates an end effector that includes an anvil, an elongate channel, and a staple cartridge, and fig. 136B is a close-up view illustrating an anvil that further includes a magnet and an inner surface that further includes a plurality of staple forming indentations;

137A-137C illustrate one embodiment of an end effector that is operable to form an electrical connection with a proximal contact point, wherein fig. 137A illustrates an end effector comprising an anvil, an elongate channel, and a staple cartridge, fig. 137B is a close-up view of a pin disposed within a hole defined in the elongate channel for this purpose, and fig. 137C illustrates an alternative embodiment wherein a second conductive surface on the surface of the hole has an alternative location;

FIG. 138 shows an embodiment of an end effector with a distal sensor plug;

FIG. 139A shows the end effector shown in FIG. 138 with the anvil in the open position;

FIG. 139B depicts a cross-sectional view of the end effector depicted in FIG. 139A with the anvil in the open position;

FIG. 139C depicts the end effector depicted in FIG. 138 with the anvil in the closed position;

FIG. 139D depicts a cross-sectional view of the end effector depicted in FIG. 139C with the anvil in the closed position;

FIG. 140 provides a close-up view of a cross-section of the distal end of the end effector;

FIG. 141 shows a close-up top view of a staple cartridge including a distal sensor plug;

FIG. 142A is a perspective view of the underside of a staple cartridge including a distal sensor plug;

FIG. 142B shows a cross-sectional view of the distal end of the staple cartridge;

FIGS. 143A-143C illustrate one embodiment of a staple cartridge including a flexible cable connected to a Hall effect sensor and a processor, wherein FIG. 143A is an exploded view of the staple cartridge, FIG. 143B illustrates the assembly of the staple cartridge and the flexible cable in greater detail, and FIG. 143C illustrates a cross-sectional view of the staple cartridge according to the present embodiment to illustrate the arrangement of the Hall effect sensor, the processor, and the conductive coupling within the distal end of the staple cartridge;

144A-144F illustrate one embodiment of a staple cartridge comprising flexible cables connected to a hall effect sensor and a processor, wherein fig. 144A is an exploded view of the staple cartridge, fig. 144B illustrates assembly of the staple cartridge, fig. 144C illustrates an underside of the assembled staple cartridge and further illustrates the flexible cables in greater detail, fig. 144D illustrates a cross-sectional view of the staple cartridge to illustrate the arrangement of the hall effect sensor, the processor, and the conductive coupler, fig. 144E illustrates an underside of the staple cartridge without a cartridge tray and including a wedge sled in its distal-most position, and fig. 144F illustrates the staple cartridge without a cartridge tray to illustrate possible arrangements of cable traces;

FIGS. 145A and 145B illustrate one embodiment of a staple cartridge comprising a flexible cable, a Hall effect sensor, and a processor, wherein FIG. 145A is an exploded view of the staple cartridge and FIG. 145B illustrates the assembly of the staple cartridge and the flexible cable in greater detail;

FIG. 146A shows a perspective view of an end effector coupled to a shaft assembly;

FIG. 146B illustrates a perspective view of the underside of the end effector and shaft assembly shown in FIG. 146A;

FIG. 146C shows the end effector shown in FIGS. 146A and 146B with the flexible cables and without the shaft assembly;

FIGS. 146D and 146E illustrate the elongate channel portion of the end effector shown in FIGS. 146A and 146B without an anvil or staple cartridge to illustrate how the flexible cables shown in FIG. 146C may be placed within the elongate channel;

FIG. 146F depicts the flexible cable of FIGS. 146C-120E, 146C-146E in isolation;

FIG. 147 illustrates a close-up view of the elongate channel illustrated in FIGS. 146D and 146E having a staple cartridge coupled thereto;

fig. 148A-148D further illustrate one embodiment of a staple cartridge operating with the present embodiment of an end effector, wherein fig. 148A illustrates a close-up view of the proximal end of the staple cartridge, fig. 148B illustrates a close-up view of the distal end of the staple cartridge with space for a distal sensor plug, fig. 148C further illustrates a distal sensor plug, and fig. 148D illustrates a proximal-facing side of the distal sensor plug;

Fig. 149A and 149B illustrate one embodiment of a distal sensor plug, wherein fig. 149A illustrates a cross-sectional view of the distal sensor plug and fig. 149B further illustrates a hall effect sensor and processor operably coupled to the flex plate to enable them to communicate;

fig. 150 illustrates an embodiment of an end effector having a flexible cable operable to provide power to sensors and electronics in the distal tip of the anvil portion;

151A-151C illustrate operation of the articulation joints and flexible cables of the end effector, wherein FIG. 151A illustrates a top view of the end effector with the end effector pivoted-45 degrees relative to the shaft assembly, FIG. 151B illustrates a top view of the end effector, and FIG. 151C illustrates a top view of the end effector with the end effector pivoted +45 degrees relative to the shaft assembly;

FIG. 152 shows a cross-sectional view of the distal tip of an embodiment of an anvil having sensors and electronics; and is

Fig. 153 shows a cross-sectional view of the distal tip of the anvil.

Description of the invention

Certain exemplary embodiments will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the devices and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of embodiments of the present invention.

Reference throughout this specification to "various embodiments," "some embodiments," "one embodiment," or "an embodiment," etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases "in various embodiments," "in some embodiments," "in one embodiment," or "in an embodiment," or the like, throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, a particular feature, structure, or characteristic shown or described in connection with one embodiment may be combined, in whole or in part, with features, structures, or characteristics of one or more other embodiments, without limitation. Such modifications and variations are intended to be included within the scope of embodiments of the present invention.

The terms "proximal" and "distal" are used herein with respect to a clinician manipulating a handle portion of a surgical instrument. The term "proximal" refers to the portion closest to the clinician and the term "distal" refers to the portion located away from the clinician. It will be further appreciated that, for simplicity and clarity, spatial terms such as "vertical," "horizontal," "up," and "down" may be used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute.

Various example devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, one of ordinary skill in the art will readily appreciate that the various methods and devices disclosed herein may be used in a number of surgical procedures and applications, including, for example, in conjunction with open surgery. With continued reference to the present detailed description, those of ordinary skill in the art will further appreciate that the various instruments disclosed herein may be inserted into the body in any manner, such as through a natural orifice, through an incision or puncture formed in tissue, and the like. The working portion or end effector portion of the instrument may be inserted directly into the patient or may be inserted through an access device having a working channel through which the end effector and elongate shaft of the surgical instrument may be advanced.

Fig. 1-6 illustrate a reusable or non-reusable motor driven surgical cutting and fastening instrument 10. In the illustrated embodiment, the instrument 10 includes a housing 12 including a handle 14 configured to be grasped, manipulated, and actuated by a clinician. The housing 12 is configured for operable attachment to an interchangeable shaft assembly 200 having a surgical end effector 300 operably coupled thereto that is configured to perform one or more surgical tasks or procedures. With continued reference to the present detailed description, it should be understood that the various unique and novel configurations of the various forms of interchangeable shaft assemblies disclosed herein may also be effectively utilized in connection with robotically controlled surgical systems. Thus, the term "housing" may also encompass a housing or similar portion of a robotic system that houses or otherwise operably supports at least one drive system configured to generate and apply at least one control action useful for actuating the interchangeable shaft assemblies disclosed herein and their respective equivalents. The term "frame" may refer to a portion of a hand-held surgical instrument. The term "frame" may also refer to a portion of a robotically-controlled surgical instrument and/or a portion of a robotic system that may be used to operably control a surgical instrument. For example, the interchangeable shaft assemblies disclosed herein may be used WITH various robotic systems, INSTRUMENTS, components, and methods disclosed in U.S. patent application serial No. 13/118,241 (now U.S. patent application publication No. US 2012/0298719), entitled "SURGICAL INSTRUMENTS WITH rotabable stage design. U.S. patent application Ser. No. 13/118,241 (now U.S. patent application publication US 2012/0298719), entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS," is hereby incorporated by reference in its entirety.

The housing 12 shown in fig. 1-3 is shown in connection with an interchangeable shaft assembly 200 that includes an end effector 300 that includes a surgical cutting and fastening device configured to operably support a surgical staple cartridge 304 therein. Housing 12 may be configured for use with interchangeable shaft assemblies that include end effectors adapted to support different sizes and types of staple cartridges, and have different shaft lengths, sizes, types, and the like. In addition, housing 12 may also be effectively used with a variety of other interchangeable shaft assemblies, including those configured to apply other motions and energy forms, such as Radio Frequency (RF) energy, ultrasonic energy, and/or motions, to end effector configurations suitable for use in connection with various surgical applications and surgical procedures. Further, the end effector, shaft assembly, handle, surgical instrument, and/or surgical instrument system may utilize any suitable fastener or fasteners to fasten tissue. For example, a fastener cartridge including a plurality of fasteners removably stored therein can be removably inserted and/or attached to an end effector of a shaft assembly.

Fig. 1 illustrates a surgical instrument 10 having an interchangeable shaft assembly 200 operably coupled thereto. Fig. 2 and 3 show the interchangeable shaft assembly 200 attached to the housing 12 or handle 14. As shown in fig. 4, the handle 14 may include a pair of interconnectable handle housing segments 16 and 18 that may be interconnected by screws, snap features, adhesives, and the like. In the illustrated construction, the handle housing segments 16, 18 cooperate to form a pistol grip portion 19 that can be grasped and manipulated by a clinician. As will be discussed in further detail below, the handle 14 operably supports a plurality of drive systems therein that are configured to generate and apply various control motions to corresponding portions of the interchangeable shaft assembly operably attached thereto.

Referring now to fig. 4, the handle 14 may further include a frame 20 that operably supports a plurality of drive systems. For example, the frame 20 can operably support a "first" or closure drive system, generally designated 30, which can be used to apply closing and opening motions to the interchangeable shaft assembly 200 operably attached or coupled thereto. In at least one form, the closure drive system 30 can include an actuator in the form of a closure trigger 32 pivotally supported by the frame 20. More specifically, as shown in FIG. 4, the closure trigger 32 is pivotally coupled to the housing 14 via a pin 33. This configuration enables the closure trigger 32 to be manipulated by the clinician such that when the clinician grasps the pistol grip portion 19 of the handle 14, the closure trigger 32 can be easily pivoted by the clinician from the starting or "unactuated" position to the "actuated" position, and more specifically, to the fully compressed or fully actuated position. The closure trigger 32 may be biased to an unactuated position by a spring or other biasing structure (not shown). In various forms, the closure drive system 30 also includes a closure link assembly 34 that is pivotally coupled to the closure trigger 32. As shown in FIG. 4, the closure link assembly 34 may include a first closure link 36 and a second closure link 38 pivotally coupled to the closure trigger 32 by a pin 35. The second closure link 38 may also be referred to herein as an "attachment member" and includes a lateral attachment pin 37.

Still referring to fig. 4, it can be observed that the first closure link 36 can have a locking wall or locking end 39 thereon that is configured to mate with a closure release assembly 60 pivotally coupled to the frame 20. In at least one form, the closure release assembly 60 can include a release button assembly 62 having a distally projecting locking pawl 64 formed thereon. The release button assembly 62 may be pivoted in a counterclockwise direction by a release spring (not shown). As the clinician depresses the closure trigger 32 from its unactuated position toward the pistol grip portion 19 of the handle 14, the first closure link 36 pivots upward to a point where the locking pawl 64 drops into engagement with the locking wall 39 on the first closure link 36, thereby preventing the closure trigger 32 from returning to the unactuated position. See fig. 18. Thus, the closure release assembly 60 functions to lock the closure trigger 32 in the fully actuated position. When the clinician desires to unlock the closure trigger 32 to allow it to be biased to the unactuated position, the clinician need only pivot the closure release button assembly 62 such that the locking pawl 64 moves out of engagement with the locking wall 39 on the first closure link 36. When the locking pawl 64 has moved out of engagement with the first closure link 36, the closure trigger 32 may pivot back to the unactuated position. Other closure trigger locking and release configurations may also be employed.

In addition to the above, fig. 13-15 illustrate the closure trigger 32 in an unactuated position associated with an open or unclamped configuration of the shaft assembly 200 in which tissue may be positioned between the jaws of the shaft assembly 200. Fig. 16-18 illustrate the closure trigger 32 in an actuated position associated with a closed or clamped configuration of the shaft assembly 200 in which tissue is clamped between the jaws of the shaft assembly 200. The reader will appreciate after comparing fig. 14 to fig. 17 that the closure release button 62 pivots between a first position (fig. 14) and a second position (fig. 17) when the closure trigger 32 is moved from its unactuated position (fig. 14) to its actuated position (fig. 17). Rotation of the closure release button 62 may be referred to as upward rotation, however, at least a portion of the closure release button 62 rotates toward the circuit board 100. Referring to fig. 4, the closure release button 62 may include an arm 61 extending therefrom and a magnetic element 63 (such as a permanent magnet) mounted to the arm 61. When the closure release button 62 is rotated from its first position to its second position, the magnetic element 63 may move toward the circuit board 100. The circuit board 100 may include at least one sensor configured to detect movement of the magnetic element 63. In at least one embodiment, for example, the hall effect sensor 65 may be mounted to a bottom surface of the circuit board 100. The hall effect sensor 65 may be configured to detect a change in the magnetic field surrounding the hall effect sensor 65 caused by the movement of the magnetic element 63. The hall effect sensor 65 may be in signal communication with, for example, a microcontroller 1500 (fig. 19) that can determine whether the closure release button 62 is in its first position associated with the unactuated position of the closure trigger 32 and the open configuration of the end effector, its second position associated with the actuated position of the closure trigger 32 and the closed configuration of the end effector, or any position between the first position and the second position.

In at least one form, the handle 14 and frame 20 can operably support another drive system, referred to herein as a firing drive system 80, that is configured to apply a firing motion to corresponding portions of an interchangeable shaft assembly attached thereto. The firing drive system 80 may also be referred to herein as a "secondary drive system". The firing drive system 80 may employ an electric motor 82 located in the pistol grip portion 19 of the handle 14. In various forms, the motor 82 may be a direct current brushed drive motor having a maximum rotational speed of approximately, for example, 25,000 RPM. In other constructions, the motor may include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The motor 82 may be powered by a power source 90, which in one form may include a removable power pack 92. As shown in fig. 4, for example, the power pack 92 may include a proximal housing portion 94 configured for attachment to a distal housing portion 96. The proximal housing portion 94 and the distal housing portion 96 are configured to operably support a plurality of batteries 98 therein. Each of the batteries 98 may include, for example, a lithium ion ("LI") battery or other suitable battery. The distal housing portion 96 is configured for removable operable attachment to a control circuit board assembly 100 that is also operably coupled to the motor 82. A plurality of batteries 98, which may be connected in series, may be used as a power source for the surgical instrument 10. Further, the power source 90 may be replaceable and/or rechargeable.

As outlined above with respect to the other various forms, the electric motor 82 may include a rotatable shaft (not shown) operably interfacing with a gear reducer assembly 84 mounted in meshing engagement with a set or rack of drive teeth 122 on the longitudinally movable drive member 120. In use, the polarity of the voltage provided by the power source 90 may operate the electric motor 82 in a clockwise direction, wherein the polarity of the voltage applied by the battery to the electric motor may be reversed to operate the electric motor 82 in a counterclockwise direction. When the electric motor 82 is rotated in one direction, the drive member 120 will be driven axially in the distal direction "DD". When the motor 82 is driven in the opposite rotational direction, the drive member 120 will be driven axially in the proximal direction "PD". The handle 14 may include a switch configured to reverse the polarity applied to the electric motor 82 by the power source 90. As with other versions described herein, the handle 14 may also include a sensor configured to detect the position of the drive member 120 and/or the direction of movement of the drive member 120.

Actuation of the motor 82 may be controlled by a firing trigger 130 that is pivotally supported on the handle 14. The firing trigger 130 may be pivotable between an unactuated position and an actuated position. The firing trigger 130 may be biased to an unactuated position by a spring 132 or other biasing configuration such that when the clinician releases the firing trigger 130, the firing trigger may be pivoted to or otherwise returned to the unactuated position by the spring 132 or biasing configuration. In at least one form, the firing trigger 130 can be positioned "outside" the closure trigger 32, as discussed above. In at least one form, the firing trigger safety button 134 may be pivotally mounted to the closure trigger 32 by a pin 35. A safety button 134 may be positioned between the firing trigger 130 and the closure trigger 32 and have a pivoting arm 136 protruding therefrom. See fig. 4. When the closure trigger 32 is in the unactuated position, the safety button 134 is housed in the handle 14 where it may not be easily accessible to the clinician and moved between a safety position preventing actuation of the firing trigger 130 and a firing position in which the firing trigger 130 may be fired. When the clinician depresses the closure trigger 32, the safety button 134 and the firing trigger 130 pivot downward and may then be manipulated by the clinician.

As discussed above, the handle 14 may include a closure trigger 32 and a firing trigger 130. Referring to fig. 14-18A, the firing trigger 130 can be pivotally mounted to the closure trigger 32. The closure trigger 32 may include an arm 31 extending therefrom, and the firing trigger 130 may be pivotally mounted to the arm 31 about a pivot pin 33. As outlined above, the firing trigger 130 may descend downwardly as the closure trigger 32 moves from its unactuated position (FIG. 14) to its actuated position (FIG. 17). After the safety button 134 has been moved to its firing position, referring primarily to FIG. 18A, the firing trigger 130 may be depressed to operate the motor of the surgical instrument firing system. In various instances, the handle 14 can include a tracking system (such as system 800) configured to determine the position of the closure trigger 32 and/or the position of the firing trigger 130. Referring primarily to fig. 14, 17, and 18A, the tracking system 800 may include a magnetic element (such as a permanent magnet 802) mounted to an arm 801 extending from the firing trigger 130. The tracking system 800 may include one or more sensors, such as a first hall effect sensor 803 and a second hall effect sensor 804, which may be configured to track the position of the magnet 802. The reader will appreciate after comparing fig. 14 to fig. 17 that the magnet 802 is movable between a first position adjacent the first hall effect sensor 803 and a second position adjacent the second hall effect sensor 804 when the closure trigger 32 is moved from its unactuated position to its actuated position. The reader will further appreciate after comparing FIG. 17 with FIG. 18A that the magnet 802 may move relative to the second Hall effect sensor 804 as the firing trigger 130 moves from the unfired position (FIG. 17) to the fired position (FIG. 18A). The sensors 803 and 804 may track the movement of the magnet 802 and may be in signal communication with a microcontroller on the circuit board 100. The microcontroller may determine the position of the magnet 802 along the predefined path using data from the first sensor 803 and/or the second sensor 804, and based on that position, the microcontroller may determine whether the closure trigger 32 is in its unactuated position, its actuated position, or a position between its unactuated position and its actuated position. Similarly, the microcontroller may determine the position of the magnet 802 along the predefined path using data from the first sensor 803 and/or the second sensor 804, and based on that position, the microcontroller may determine whether the firing trigger 130 is in its unfired position, its fully fired position, or a position between its unfired position and its fully fired position.

As mentioned above, in at least one form, the longitudinally movable drive member 120 has rack teeth 122 formed thereon for meshing engagement with the corresponding drive gear 86 of the gear reducer assembly 84. At least one form further includes a manually actuatable "panic" assembly 140 configured to allow a clinician to manually retract the longitudinally movable drive member 120 should the motor 82 become deactivated. The panic assembly 140 may include a lever or panic handle assembly 142 configured to be manually pivoted into ratcheting engagement with the teeth 124 also provided in the drive member 120. Thus, the clinician may manually retract the drive member 120 using the emergency handle assembly 142 to ratchet the drive member 120 in the proximal direction "PD". U.S. patent application publication US 2010/0089970 discloses emergency configurations, and other components, configurations, and systems that may also be used with the various instruments disclosed herein. U.S. patent application Ser. No. 12/249,117 (now U.S. patent application publication 2010/0089970), entitled "POWER SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM," is hereby incorporated by reference in its entirety.

Turning now to fig. 1 and 7, the interchangeable shaft assembly 200 includes a surgical end effector 300 that includes an elongate channel 302 configured to operably support a staple cartridge 304 therein. The end effector 300 may also include an anvil 306 that is pivotally supported relative to the elongate channel 302. The interchangeable shaft assembly 200 can further include an articulation joint 270 and an articulation lock 350 (fig. 8) that can be configured to releasably retain the end effector 300 in a desired position relative to the shaft axis SA-SA. Details regarding the construction and operation of the end effector 300, ARTICULATION joint 270 and ARTICULATION LOCK 350 are shown in U.S. patent application serial No. 13/803,086 entitled "ARTICULATION joint locking system", filed on 3, 14, 2013. The entire disclosure of U.S. patent application serial No. 13/803,086 entitled "article able document compatibility AN article location LOCK", filed on 14/3/2013, is hereby incorporated by reference. As shown in fig. 7 and 8, the interchangeable shaft assembly 200 can also include a proximal housing or nozzle 201 comprised of nozzle portions 202 and 203. The interchangeable shaft assembly 200 can also include a closure tube 260 that can be used to close and/or open the anvil 306 of the end effector 300. Referring now primarily to fig. 8 and 9, the shaft assembly 200 may include a ridge 210, which may be configured to fixably support the shaft frame portion 212 of the articulation lock 350. See fig. 8. The ridge 210 may be configured to: first, a firing member 220 is slidably supported therein; second, the closure tube 260, which extends around the spine 210, is slidably supported. The spine 210 is also configured to slidably support a proximal articulation driver 230. Articulation driver 230 has a distal end 231 configured to operably engage articulation lock 350. The articulation lock 350 interfaces with an articulation frame 352 that is configured to operably engage a drive pin (not shown) on an end effector frame (not shown). As mentioned above, more details regarding the operation of the articulation lock 350 and the articulation frame may be found in U.S. patent application Ser. No. 13/803,086. In various instances, the spine 210 may include a proximal end 211 rotatably supported in the base 240. In one configuration, for example, the proximal end 211 of the spine 210 has threads 214 formed thereon for threaded attachment to a spine bearing 216 configured to be supported within the base 240. See fig. 7. This configuration facilitates rotatably attaching the ridge 210 to the base 240 such that the ridge 210 may be selectively rotated relative to the base 240 about the axis SA-SA.

Referring primarily to FIG. 7, the interchangeable shaft assembly 200 includes a closure shuttle 250 slidably supported within the base 240 in an axially movable manner relative thereto. As shown in fig. 3 and 7, the closure shuttle 250 includes a pair of proximally projecting hooks 252 configured to attach to an attachment pin 37 attached to the second closure link 38, as will be discussed in further detail below. The proximal end 261 of the closure tube 260 is coupled to the closure shuttle 250 for rotation relative thereto. For example, the U-shaped connector 263 is inserted into the annular slot 262 in the proximal end 261 of the closure tube 260 such that it remains within the vertical slot 253 in the closure shuttle 250. See fig. 7. This configuration serves to attach the closure tube 260 to the closure shuttle 250 for axial travel therewith while enabling the closure tube 260 to rotate relative to the closure shuttle 250 about the shaft axis SA-SA. A closure spring 268 is journaled on the closure tube 260 for biasing the closure tube 260 in the proximal direction "PD" and is operable to pivot the closure trigger to an unactuated position when the shaft assembly is operably coupled to the handle 14.

In at least one form, the interchangeable shaft assembly 200 can further include an articulation joint 270. However, other interchangeable shaft assemblies may not be capable of articulation. As shown in FIG. 7, for example, the articulation joint 270 includes a dual pivot closure sleeve assembly 271. According to various forms, the double pivot closure sleeve assembly 271 includes an end effector closure sleeve assembly 272 having distally projecting upper and lower tangs 273, 274. End effector closure sleeve assembly 272 includes horseshoe aperture 275 and tab 276 for engaging the open tab on anvil 306 in the various manners described in U.S. patent application serial No. 13/803,086 entitled "article able to be moved into position on AN article closed LOCK," filed on 3, 14, 2013, which is incorporated herein by reference. As described in further detail herein, when the anvil 306 is opened, the horseshoe aperture 275 and tab 276 engage the tab on the anvil. The upper dual pivot link 277 includes upwardly projecting distal and proximal pivot pins that engage upper distal pin holes in the upper proximally projecting tang 273 and upper proximal pin holes in the upper distally projecting tang 264, respectively, on the closure tube 260. The lower dual pivot link 278 includes upwardly projecting distal and proximal pivot pins that engage respectively a lower distal pin hole in the proximally projecting inferior tang 274 and a lower proximal pin hole in the distally projecting inferior tang 265. See also fig. 8.

In use, the closure tube 260 is translated distally (direction "DD") to close the anvil 306, for example, in response to actuation of the closure trigger 32. By translating the closure tube 260 distally, and thus the shaft closure sleeve assembly 272, the shaft closure sleeve assembly is caused to impact a proximal surface on the anvil 360, thereby closing the anvil 306, in the manner described in the aforementioned reference U.S. patent application serial No. 13/803,086. As also detailed in this reference, the anvil 306 is opened by translating the closure tube 260 and shaft closure sleeve assembly 272 proximally, causing the tab 276 and horseshoe aperture 275 to contact and push against the anvil tab to lift the anvil 306. In the anvil open position, the shaft closure tube 260 is moved to its proximal position.

As mentioned above, the surgical instrument 10 may also include an articulation lock 350 of the type and configuration described in further detail in U.S. patent application Ser. No. 13/803,086, which may be configured to be operable to selectively lock the end effector 300 in place. This configuration enables the end effector 300 to rotate or articulate relative to the shaft closure tube 260 when the articulation lock 350 is in its unlocked state. In this unlocked state, the end effector 300 may be positioned and urged against, for example, soft tissue and/or bone surrounding a surgical site within a patient to articulate the end effector 300 relative to the closure tube 260. The end effector 300 may also be articulated relative to the closure tube 260 by the articulation driver 230.

Also as described above, the interchangeable shaft assembly 200 further includes a firing member 220 that is supported for axial travel within the shaft spine 210. The firing member 220 includes an intermediate firing shaft portion 222 that is configured to be attached to a distal cutting portion or knife bar 280. The firing member 220 may also be referred to herein as a "second shaft" and/or a "second shaft assembly". As shown in fig. 8 and 9, the intermediate firing shaft portion 222 can include a longitudinal slot 223 in a distal end thereof that can be configured to receive a tab 284 on a proximal end 282 of the distal knife bar 280. The longitudinal slot 223 and the proximal end 282 may be sized and configured to allow relative movement therebetween, and may include a slip joint 286. The slip joint 286 can allow the intermediate firing shaft portion 222 of the firing drive 220 to move to articulate the end effector 300 without moving, or at least substantially moving, the knife bar 280. Once the end effector 300 has been properly oriented, the intermediate firing shaft portion 222 can be advanced distally until the proximal side wall of the longitudinal slot 223 contacts the tab 284 in order to advance the knife bar 280 and fire a staple cartridge positioned within the channel 302. As can be further seen in fig. 8 and 9, the shaft spine 210 has an elongated opening or window 213 therein to facilitate assembly and insertion of the intermediate firing shaft portion 222 into the shaft frame 210. Once the intermediate firing shaft portion 222 has been inserted into the shaft frame, the top frame segment 215 may be engaged with the shaft frame 212 to enclose the intermediate firing shaft portion 222 and the knife bar 280 therein. Further description of the operation of the firing member 220 may be found in U.S. patent application serial No. 13/803,086.

In addition to the above, the shaft assembly 200 can include a clutch assembly 400 that can be configured to selectively and releasably couple the articulation driver 230 to the firing member 220. In one form, the clutch assembly 400 includes a lock collar or lock sleeve 402 positioned about the firing member 220, wherein the lock sleeve 402 is rotatable between an engaged position in which the lock sleeve 402 couples the articulation driver 360 to the firing member 220 and a disengaged position in which the articulation driver 360 is not operably coupled to the firing member 200. When the lock sleeve 402 is in its engaged position, distal movement of the firing member 220 can move the articulation driver 360 distally and, correspondingly, proximal movement of the firing member 220 can move the articulation driver 230 proximally. When the lock sleeve 402 is in its disengaged position, the motion of the firing member 220 is not transferred to the articulation driver 230 and, therefore, the firing member 220 may move independently of the articulation driver 230. In various circumstances, the articulation driver 230 may be held in place by the articulation lock 350 when the articulation driver 230 is not moved in the proximal or distal direction by the firing member 220.

Referring primarily to FIG. 9, the lock sleeve 402 can include a cylindrical or at least substantially cylindrical body including a longitudinal bore 403 defined therein configured to receive the firing member 220. The locking sleeve 402 may include an inwardly facing locking protrusion 404 and an outwardly facing locking member 406, which are diametrically opposed. The lock protrusion 404 can be configured to selectively engage with the firing member 220. More specifically, with the lock sleeve 402 in its engaged position, the lock protrusion 404 is positioned within the drive notch 224 defined in the firing member 220 such that a distal pushing force and/or a proximal pulling force can be transmitted from the firing member 220 to the lock sleeve 402. When the locking sleeve 402 is in its engaged position, the second locking member 406 is received within a drive notch 232 defined in the articulation driver 230 such that a distal pushing force and/or a proximal pulling force applied to the locking sleeve 402 may be transmitted to the articulation driver 230. In fact, when the lock sleeve 402 is in its engaged position, the firing member 220, the lock sleeve 402, and the articulation driver 230 will move together. On the other hand, when the lock sleeve 402 is in its disengaged position, the lock protrusion 404 may not be positioned within the drive notch 224 of the firing member 220, and thus, a distal pushing force and/or a proximal pulling force may not be transmitted from the firing member 220 to the lock sleeve 402. Accordingly, the distal pushing force and/or the proximal pulling force may not be transmitted to the articulation driver 230. In this instance, the firing member 220 can slide proximally and/or distally relative to the lock sleeve 402 and the proximal articulation driver 230.

As shown in fig. 8-12, the shaft assembly 200 further includes a switch drum 500 rotatably received on the closure tube 260. The switching drum 500 includes a hollow shaft segment 502 having a shaft boss 504 formed thereon for receiving the outwardly projecting actuating pin 410 therein. In various circumstances, the actuation pin 410 extends through the slot 267 into a longitudinal slot 408 provided in the locking sleeve 402 to facilitate axial movement of the locking sleeve 402 when engaged with the articulation driver 230. The rotary torsion spring 420 is configured to engage a boss 504 on the switch drum 500 and a portion of the nozzle housing 203 to apply a biasing force to the switch drum 500 as shown in fig. 10. Referring to fig. 5 and 6, the switch drum 500 may further include at least partially peripheral openings 506 defined therein, which may be configured to receive the peripheral mounts 204, 205 extending from the nozzle halves 202, 203 and allow relative rotation, but not translation, between the switch drum 500 and the proximal nozzle 201. As shown in these figures, the mounts 204 and 205 also extend through openings 266 in the closure tube 260 to seat in the recesses 211 in the shaft ridge 210. However, rotation of the nozzle 201 to a point at which the mounting brackets 204, 205 reach the end of their respective slots 506 in the switch drum 500 will cause the switch drum 500 to rotate about the shaft axis SA-SA. Rotation of the switching drum 500 will eventually cause the actuating pin 410 to rotate and cause the locking sleeve 402 to rotate between its engaged and disengaged positions. Thus, the nozzle 201 may be used to operably engage and disengage an articulation drive system from a firing drive system in a variety of ways as described in further detail in U.S. patent application serial No. 13/803,086.

As also shown in fig. 8-12, the shaft assembly 200 can include a slip ring assembly 600, which can be configured to conduct electrical power to and/or from the end effector 300, and/or transmit and/or receive signals to and/or from the end effector 300, for example. The slip ring assembly 600 may include a proximal connector flange 604 mounted to a base flange 242 extending from the base 240 and a distal connector flange 601 positioned within a slot defined in the shaft housings 202, 203. The proximal connector flange 604 can comprise a first face and the distal connector flange 601 can comprise a second face, wherein the second face is positioned adjacent to and movable relative to the first face. The distal connector flange 601 is rotatable relative to the proximal connector flange 604 about the shaft axis SA-SA. The proximal connector flange 604 may include a plurality of concentric or at least substantially concentric conductors 602 defined in a first face thereof. The connector 607 may be mounted on the proximal side of the connector flange 601 and may have a plurality of contacts (not shown) where each contact corresponds to and makes electrical contact with one of the conductors 602. This configuration allows for relative rotation between the proximal connector flange 604 and the distal connector flange 601 while maintaining electrical contact therebetween. For example, the proximal connector flange 604 may include an electrical connector 606 that may place the conductor 602 in signal communication with a shaft circuit board 610 mounted to the shaft base 240. In at least one instance, a wire harness including a plurality of conductors can extend between the electrical connector 606 and the shaft circuit board 610. The electrical connector 606 may extend proximally through a connector opening 243 defined in the chassis mounting flange 242. See fig. 7. U.S. patent application serial No. 13/800,067 entitled "STAPLE CARTRIDGE TISSUE thicknes SENSOR SYSTEM," filed on 3/13/2013, is hereby incorporated by reference in its entirety. U.S. patent application serial No. 13/800,025 entitled "STAPLE CARTRIDGE TISSUE thicknes SENSOR SYSTEM," filed on 3/13/2013, is hereby incorporated by reference in its entirety. More details regarding slip ring assembly 600 may be found in U.S. patent application serial No. 13/803,086.

As discussed above, the shaft assembly 200 can include a proximal portion that can be fixedly mounted to the handle 14 and a distal portion that can rotate about a longitudinal axis. As discussed above, the rotatable distal shaft portion may be rotated relative to the proximal portion about the slip ring assembly 600. The distal connector flange 601 of the slip ring assembly 600 may be positioned within the rotatable distal shaft portion. Also, in addition to the above, the switch drum 500 may be positioned within a rotatable distal shaft portion. When the rotatable distal shaft portion is rotated, the distal connector flange 601 and the switch drum 500 may be rotated in synchronization with each other. Additionally, the switch drum 500 is rotatable relative to the distal connector flange 601 between a first position and a second position. When the switch drum 500 is in its first position, the articulation drive system may be operably disengaged from the firing drive system and, as a result, operation of the firing drive system may not articulate the end effector 300 of the shaft assembly 200. When the switch drum 500 is in its second position, the articulation drive system can be operably engaged with the firing drive system such that operation of the firing drive system can articulate the end effector 300 of the shaft assembly 200. When the switch drum 500 is moved between its first position and its second position, the switch drum 500 moves relative to the distal connector flange 601. In various instances, the shaft assembly 200 can include at least one sensor configured to detect the position of the switch drum 500. Turning now to fig. 11 and 12, the distal connector flange 601 may include, for example, a hall effect sensor 605, and the switch drum 500 may include, for example, a magnetic element, such as permanent magnet 505. The hall effect sensor 605 may be configured to detect the position of the permanent magnet 505. The permanent magnet 505 may move relative to the hall effect sensor 605 when the switch drum 500 is rotated between its first position and its second position. In various circumstances, the hall effect sensor 605 can detect changes in the magnetic field that are generated when the permanent magnet 505 moves. The hall effect sensor 605 may be in signal communication with, for example, the shaft circuit board 610 and/or the handle circuit board 100. Based on the signal from the hall effect sensor 605, a microcontroller on the shaft circuit board 610 and/or the handle circuit board 100 can determine whether the articulation drive system is engaged or disengaged from the firing drive system.

Referring again to fig. 3 and 7, the base 240 includes at least one, and preferably two, tapered attachment portions 244 formed thereon that are adapted to be received within corresponding dovetail slots 702 formed within the distal attachment flange portion 700 of the frame 20. Each dovetail slot 702 may be tapered, or in other words, may be slightly V-shaped, to seatingly receive the attachment portion 244 therein. As can be further seen in fig. 3 and 7, a shaft attachment ear 226 is formed on the proximal end of the intermediate firing shaft 222. As will be discussed in further detail below, when the interchangeable shaft assembly 200 is coupled to the handle 14, the shaft attachment ears 226 are received in the firing shaft attachment brackets 126 formed in the distal end 125 of the longitudinal drive member 120. See fig. 3 and 6.

Various shaft assembly embodiments employ a latch system 710 to removably couple the shaft assembly 200 to the housing 12, and more particularly, to the frame 20. As shown in fig. 7, for example, in at least one form, the latch system 710 includes a lock member or lock yoke 712 movably coupled to the chassis 240. In the illustrated embodiment, for example, the lock yoke 712 is U-shaped having two spaced apart and downwardly extending legs 714. Each of the legs 714 has pivot ears 716 formed thereon that are adapted to be received in corresponding holes 245 formed in the base 240. This configuration facilitates pivotal attachment of the lock yoke 712 to the base 240. The lock yoke 712 may include two proximally projecting lock ears 714 configured to releasably engage with corresponding lock detents or grooves 704 in the distal attachment flange 700 of the frame 20. See fig. 3. In various forms, the lock yoke 712 is biased in a proximal direction by a spring or biasing member (not shown). Actuation of the lock yoke 712 may be accomplished by a latch button 722 slidably mounted on a latch actuator assembly 720 that is mounted to the chassis 240. The latch button 722 may be biased in a proximal direction relative to the lock yoke 712. As will be discussed in further detail below, the lock yoke 712 may be moved to the unlocked position by biasing the latch button in the distal direction, which also pivots the lock yoke 712 out of retaining engagement with the distal attachment flange 700 of the frame 20. When the lock yoke 712 is "held in engagement" with the distal attachment flange 700 of the frame 20, the lock ears 716 remain seated within the corresponding lock detents or grooves 704 in the distal attachment flange 700.

When interchangeable shaft assemblies are employed that include end effectors of the types described herein as well as other types of end effectors adapted to cut and fasten tissue, it may be advantageous to prevent the interchangeable shaft assemblies from inadvertently disengaging from the housing during actuation of the end effector. For example, in use, a clinician may actuate the closure trigger 32 to grasp and manipulate target tissue to a desired location. Once the target tissue is positioned within the end effector 300 in the desired orientation, the clinician may fully actuate the closure trigger 32 to close the anvil 306 and clamp the target tissue in place for cutting and stapling. In this case, the first drive system 30 has been fully actuated. After the target tissue has been clamped in the end effector 300, it may be advantageous to prevent the shaft assembly 200 from being inadvertently detached from the housing 12. One form of the latching system 710 is configured to prevent such inadvertent disengagement.

As can be seen most particularly in fig. 7, the lock yoke 712 includes at least one and preferably two lock hooks 718 capable of contacting corresponding lock ear portions 256 formed on the closure shuttle 250. Referring to fig. 13-15, when the closure shuttle 250 is in the unactuated position (i.e., the first drive system 30 is unactuated and the anvil 306 is open), the lock yoke 712 can be pivoted in the distal direction to unlock the interchangeable shaft assembly 200 from the housing 12. When in this position, the locking hooks 718 do not contact the locking ear portions 256 on the closure shuttle 250. However, when the closure shuttle 250 is moved to the actuated position (i.e., the first drive system 30 is actuated and the anvil 306 is in the closed position), the lock yoke 712 is prevented from pivoting to the unlocked position. See fig. 16-18. In other words, if the clinician attempts to pivot the lock yoke 712 to the unlocked position, or, for example, the lock yoke 712 is inadvertently bumped or contacted in a manner that might otherwise cause it to pivot distally, the lock hooks 718 on the lock yoke 712 will contact the lock ears 256 on the closure shuttle 250 and prevent the lock yoke 712 from moving to the unlocked position.

The operation of the interchangeable shaft assembly 200 in attachment with the handle 14 will now be described with reference to fig. 3. To begin the coupling process, the clinician may position the base 240 of the interchangeable shaft assembly 200 over or near the distal attachment flange 700 of the frame 20 such that the tapered attachment portion 244 formed on the base 240 is aligned with the dovetail slot 702 in the frame 20. The clinician may then move the shaft assembly 200 along a mounting axis IA perpendicular to the shaft axis SA-SA to seat the attachment portions 244 in "operable engagement" with the corresponding dovetail receiving slots 702. In doing so, the shaft attachment ears 226 on the intermediate firing shaft 222 will also be seated in the brackets 126 in the longitudinally movable drive member 120, and the portion of the pin 37 on the second closure link 38 will be seated in the corresponding hook 252 in the closure yoke 250. As used herein, the term "operably engaged" in the context of two components means that the two components are sufficiently engaged with each other such that upon application of an actuation motion thereto, the components may perform their intended activities, functions, and/or procedures.

As discussed above, at least five systems of the interchangeable shaft assembly 200 can be operably coupled with at least five corresponding systems of the handle 14. The first system may include a frame system that couples and/or aligns the frame or spine of the shaft assembly 200 with the frame 20 of the handle 14. The second system can include a closure drive system 30 that can operably connect the closure trigger 32 of the handle 14 with the closure tube 260 and anvil 306 of the shaft assembly 200. As outlined above, the closure tube attachment yoke 250 of the shaft assembly 200 may be engaged with the pin 37 on the second closure link 38. The third system may include a firing drive system 80 that may operably connect the firing trigger 130 of the handle 14 with the intermediate firing shaft 222 of the shaft assembly 200.

As outlined above, the shaft attachment ears 226 may be operably connected with the bracket 126 of the longitudinal drive member 120. The fourth system may include an electrical system capable of: signals that the shaft assembly (such as shaft assembly 200) has been operably engaged with the handle 14 are sent to a controller (such as a microcontroller) in the handle 14 and/or power and/or communication signals are conducted between the shaft assembly 200 and the handle 14. For example, the shaft assembly 200 can include an electrical connector 1410 operably mounted to the shaft circuit board 610. The electrical connector 1410 is configured for mating engagement with a corresponding electrical connector 1400 on the handle control board 100. Further details regarding the circuitry and control system can be found in U.S. patent application serial No. 13/803,086, the entire disclosure of which is previously incorporated herein by reference. The fifth system may consist of a latching system for releasably locking the shaft assembly 200 to the handle 14.

Referring again to fig. 2 and 3, the handle 14 may include an electrical connector 1400 that includes a plurality of electrical contacts. Turning now to fig. 19, the electrical connector 1400 may include, for example, a first contact 1401a, a second contact 1401b, a third contact 1401c, a fourth contact 1401d, a fifth contact 1401e, and a sixth contact 1401 f. Although the illustrated embodiment utilizes six contacts, other embodiments are contemplated that may utilize more than six contacts or less than six contacts.

As shown in fig. 19, the first contact 1401a may be in electrical communication with the transistor 1408, the contacts 1401b-1401e may be in electrical communication with the microcontroller 1500, and the sixth contact 1401f may be in electrical communication with ground. In some cases, one or more of the electrical contacts 1401b-1401e can be in electrical communication with one or more output channels of the microcontroller 1500, and can be energized, or have a voltage potential applied thereto, when the handle 1042 is in a powered state. In some cases, one or more of the electrical contacts 1401b-1401e may be in electrical communication with one or more input channels of the microcontroller 1500, and when the handle 14 is in a powered state, the microcontroller 1500 may be configured to detect when a voltage potential is applied to such electrical contacts. When a shaft assembly, such as shaft assembly 200, is assembled to handle 14, electrical contacts 1401a-1401f may not be in communication with one another. However, when the shaft assembly is not assembled to the handle 14, the electrical contacts 1401a-1401f of the electrical connector 1400 may be exposed, and in some cases, one or more of the contacts 1401a-1401f may be accidentally placed in electrical communication with each other. Such a situation may arise, for example, when one or more of contacts 1401a-1401f contacts a conductive material. When this occurs, for example, the microcontroller 1500 can receive the wrong input and/or the shaft assembly 200 can receive the wrong output. To address this issue, in various circumstances, the handle 14 may not be powered when a shaft assembly (such as the shaft assembly 200) is not attached to the handle 14.

In other instances, the handle 1042 can be energized when a shaft assembly, such as the shaft assembly 200, is not attached to the handle 1042. In this case, for example, the microcontroller 1500 may be configured to ignore inputs or voltage potentials applied to contacts (i.e., contacts 1401b-1401e) in electrical communication with the microcontroller 1500 until the shaft assembly is attached to the handle 14. The handle 14 may be in a powered down state, although in this case the microcontroller 1500 may be powered to operate other functions of the handle 14. To some extent, electrical connector 1400 can be in a powered down state when the voltage potential applied to electrical contacts 1401b-1401e may not affect the operation of handle 14. The reader will appreciate that even though contacts 1401b-1401e may be in a powered down state, electrical contacts 1401a and 1401f that are not in electrical communication with microcontroller 1500 may or may not be in a powered down state. For example, the sixth contact 4001f may remain in electrical communication with ground regardless of whether the handle 14 is in a powered-up or powered-down state.

Further, whether the handle 14 is in a powered-up or powered-down state, the transistor 1408 and/or any other suitable structure of transistors (such as the transistor 1410) and/or switches may be configured to control the supply of power from a power source 1404 (such as the battery 90) within the handle 14, for example, to the first electrical contact 1401 a. In various circumstances, for example, when the shaft assembly 200 is engaged with the handle 14, the shaft assembly 200 can be configured to change the state of the transistor 1408. In some cases, the hall effect sensor 1402 may be configured to switch the state of the transistor 1410, and thus the state of the transistor 1408, among other things, to ultimately supply power from the power source 1404 to the first contact 1401 a. As such, both the power circuitry and the signal circuitry coupled to the connector 1400 may be powered down when the shaft assembly is not mounted to the handle 14 and powered up when the shaft assembly is mounted to the handle 14.

In various instances, referring again to fig. 19, the handle 14 can include, for example, a hall effect sensor 1402 that can be configured to detect a detectable element, such as a magnetic element 1407 (fig. 3), located on a shaft assembly, such as the shaft assembly 200, when the shaft assembly is coupled to the handle 14. The hall effect sensor 1402 can be powered by a power source 1406, such as a battery, which can, in effect, amplify the detection signal of the hall effect sensor 1402 and communicate with the input channel of the microcontroller 1500 via the circuit shown in fig. 19. Once the microcontroller 1500 receives an input indicating that the shaft assembly has been at least partially coupled to the handle 14, and thus that the electrical contacts 1401a-1401f are no longer exposed, the microcontroller 1500 can enter its normal or powered operating state. In such an operating state, the microcontroller 1500 will evaluate the signals transmitted from the shaft assembly to one or more of the contacts 1401b-1401e and/or transmit the signals to the shaft assembly through one or more of the contacts 1401b-1401e in its normal use state. In various circumstances, it may be necessary to fully seat the shaft assembly 200 before the hall effect sensor 1402 can detect the magnetic element 1407. For example, while the hall effect sensor 1402 may be utilized to detect the presence of the shaft assembly 200, any suitable system of sensors and/or switches may be utilized to detect whether the shaft assembly has been assembled to the handle 14. As such, in addition to the above, both the power and signal circuits coupled to the connector 1400 may be powered down when the shaft assembly is not mounted to the handle 14 and powered up when the shaft assembly is mounted to the handle 14.

In various embodiments, for example, any number of magnetic sensing elements may be employed to detect whether a shaft assembly has been assembled to the handle 14. For example, technologies for magnetic field sensing include detection coils, flux gates, optical pumps, nuclear spins, superconducting quantum interferometers (SQUIDs), hall effects, anisotropic magneto-resistive forces, giant magneto-resistive forces, magnetic tunnel junctions, giant magneto-impedance, magnetostrictive/piezoelectric composites, magnetodiodes, magnetotransistors, optical fibers, magneto-optical, and magnetic sensors based on micro-electromechanical systems, among others.

Referring to fig. 19, microcontroller 1500 can generally include a microprocessor ("processor") and one or more memory units operatively coupled to the processor. The processor, by executing the instruction codes stored in the memory, may control various components of the surgical instrument, such as the motor, various drive systems, and/or a user display. The microcontroller 1500 may be implemented using integrated and/or discrete hardware elements, software elements, and/or a combination of both hardware and software elements. Examples of integrated hardware elements may include processors, microprocessors, microcontrollers, integrated circuits, Application Specific Integrated Circuits (ASICs), Programmable Logic Devices (PLDs), Digital Signal Processors (DSPs), Field Programmable Gate Arrays (FPGAs), logic gates, registers, semiconductor devices, chips, microchips, chip sets, microcontrollers, system-on-chip (SoC), and/or package-on-Systems (SIPs). Examples of discrete hardware elements may include circuits and/or circuit elements, such as logic gates, field effect transistors, bipolar transistors, resistors, capacitors, inductors, and/or relays. In some cases, for example, microcontroller 1500 can include a hybrid circuit that includes discrete and integrated circuit elements or components on one or more substrates.

Referring to FIG. 19, microcontroller 1500 can be, for example, LM4F230H5QR, available from Texas Instruments. In some cases, the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F processor core, comprising: 256KB of on-chip memory of single cycle flash memory or other non-volatile memory (up to 40MHz), prefetch buffer to improve performance beyond 40MHz, 32KB of single cycle Serial Random Access Memory (SRAM), load with

Internal Read Only Memory (ROM) for software, 2KB Electrically Erasable Programmable Read Only Memory (EEPROM), one or more Pulse Width Modulation (PWM) modules, one or more Quadrature Encoder Input (QEI) analog, one or more 12-bit analog-to-digital converters (ADCs) with 12 analog input channels, and other features readily available. Other microcontrollers may be readily substituted for use in conjunction with the present disclosure. Accordingly, the present disclosure should not be limited to this context.

As discussed above, when the shaft assembly 200 is not assembled or not fully assembled to the handle 14, the handle 14 and/or the shaft assembly 200 may include the following systems and structures: these systems and structures are configured to prevent or at least reduce the likelihood of shorting the contacts of the handle electrical connector 1400 and/or the contacts of the shaft electrical connector 1410. Referring to fig. 3, the handle electrical connector 1400 may be at least partially recessed within a cavity 1409 defined in the handle frame 20. The six contacts 1401a-1401f of the electrical connector 1400 may be fully recessed within the cavity 1409. Such a configuration may reduce the likelihood of an object accidentally touching one or more of the contacts 1401a-1401 f. Similarly, the shaft electrical connector 1410 may be positioned within a recess defined in the shaft base 240, which may reduce the likelihood of an object accidentally contacting one or more of the contacts 1411a-1411f of the shaft electrical connector 1410. Referring to the specific embodiment shown in FIG. 3, the shaft contacts 1411a-1411f may comprise male contacts. In at least one embodiment, for example, each shaft contact 1411a-1411f may include a flexible tab extending therefrom that may be configured to engage a corresponding handle contact 1401a-1401 f. The handle contacts 1401a-1401f may comprise female contacts. In at least one embodiment, each handle contact 1401a-1401f may include a flat surface, for example, against which the boss contact 1401a-1401f may wipe or slide and maintain a conductive engagement between the flat surface and the boss contact 1401a-1401 f. In various instances, the direction of assembly of shaft assembly 200 to handle 14 may be parallel, or at least substantially parallel, to handle contacts 1401a-1401f, such that shaft contacts 1411a-1411f slide against handle contacts 1401a-1401f when shaft assembly 200 is assembled to handle 14. In various alternative embodiments, the handle contacts 1401a-1401f may comprise male contacts and the shaft contacts 1411a-1411f may comprise female contacts. In certain alternative embodiments, the handle contacts 1401a-1401f and shaft contacts 1411a-1411f may have any suitable contact arrangement.

In various instances, the handle 14 may include a connector guard configured to at least partially cover the handle electrical connector 1400 and/or a connector guard configured to at least partially cover the shaft electrical connector 1410. The connector guard may prevent, or at least reduce the likelihood of, an object from accidentally contacting the contacts of the electrical connector when the shaft assembly is not assembled, or only partially assembled, to the handle. The connector guard may be movable. For example, the connector guard may be movable between a guarding position, in which the connector guard at least partially protects the connector, and a non-guarding position, in which the connector guard does not protect the connector, or at least provides less protection for the connector. In at least one embodiment, the position of the connector guard may be displaced when the shaft assembly is assembled to the handle. For example, if the handle includes a handle connector guard, the shaft assembly may contact and displace the handle connector guard when assembling the shaft assembly to the handle. Similarly, if the shaft assembly includes a shaft connector guard, the handle may contact and displace the shaft connector guard when assembling the shaft assembly to the handle. In various instances, the connector guard may comprise a door, for example. In at least one instance, the door can include a sloped surface that can facilitate displacement of the door in a determined direction when the door is in contact with the handle or shaft. In various circumstances, for example, the connector guard may be translated and/or rotated. In some cases, the connector shield may include at least one film covering the electrical connector contacts. This film may break when the shaft assembly is assembled to the shank. In at least one instance, the male contact of the connector may first pierce the film and then engage a corresponding contact positioned below the film.

As described above, the surgical instrument can include a system configured to selectively energize or activate contacts of an electrical connector, such as electrical connector 1400. In various instances, the contacts may transition between an inactive condition and an active condition. In some cases, the contacts may transition between a monitoring condition, a deactivated condition, and an activated condition. For example, when the shaft assembly is not yet assembled to the handle 14, the microcontroller 1500 may, for example, monitor the contacts 1401a-1401f to determine if one or more of the contacts 1401a-1401f may have been shorted. The microcontroller 1500 may be configured to apply a low voltage potential to each of the contacts 1401a-1401f and evaluate whether only minimal resistance is present at each of the contacts. Such operating conditions may include monitoring conditions. If the resistance detected at a contact is high, or exceeds a threshold resistance, the microcontroller 1500 can deactivate the contact, more than one contact, or all of the contacts. Such an operating state may include a deactivation condition. As discussed above, if the shaft assembly is assembled to the handle 14 and detected by the microcontroller 1500, the microcontroller 1500 may increase the voltage potential applied to the contacts 1401a-1401 f. Such an operational state may include an active condition.

The various shaft assemblies disclosed herein may employ sensors and various other components that require electrical communication with a controller in the housing. These shaft assemblies are typically configured to be rotatable relative to the housing, and therefore a connection to facilitate such electrical communication must be provided between two or more components that are rotatable relative to one another. When employing an end effector of the type disclosed herein, the connector configuration must be relatively robust in nature, while also being somewhat compact to fit into the connector portion of the shaft assembly.

Referring to FIG. 20, a non-limiting form of an end effector 300 is shown. As described above, the end effector 300 may include an anvil 306 and a staple cartridge 304. In this non-limiting embodiment, an anvil 306 is coupled to the elongate channel 198. For example, an aperture 199 may be defined in the elongate channel 198 that can receive a pin 152 extending from the anvil 306 and allow the anvil 306 to pivot from an open position to a closed position relative to the elongate channel 198 and staple cartridge 304. In addition, fig. 20 illustrates a firing bar 172 that is configured to longitudinally translate into the end effector 300. The firing bar 172 may be constructed of one solid section or, in various embodiments, may comprise a laminate material including, for example, a stack of steel plates. The distal protruding end of the firing bar 172 may be attached to an E-beam 178 that may (among other things) help space the anvil 306 from the staple cartridge 304 positioned in the elongate channel 198 when the anvil 306 is in the closed position. The E-beam 178 can also include a sharp cutting edge 182, the cutting edge 182 operable to sever tissue as the E-beam 178 is advanced distally through the firing bar 172. In operation, the E-beam 178 can also actuate or fire the staple cartridge 304. The staple cartridge 304 can comprise a molded cartridge body 194 that holds a plurality of staples 191 disposed on staple drivers 192 located in respective upwardly opening staple cavities 195. The wedge sled 190 is driven distally by the E-beam 178 to slide over the cartridge tray 196, which holds the various components of the replaceable staple cartridge 304 together. The wedge sled 190 cams staple drivers 192 upward to extrude staples 191 into deforming contact with the anvil 306 while the cutting surface 182 of the E-beam 178 severs clamped tissue.

In addition to the above, the E-beam 178 may include an upper pin 180 that engages the anvil 306 during firing. The E-beam 178 can also include a middle pin 184 and a foot 186 that can engage various portions of the cartridge body 194, the cartridge tray 196, and the elongate channel 198. When the staple cartridge 304 is positioned within the elongate channel 198, the slot 193 defined in the cartridge body 194 can be aligned with the slot 197 defined in the cartridge tray 196 and the slot 189 defined in the elongate channel 198. In use, the E-beam 178 can be slid through the aligned slots 193, 197, and 189, as shown in fig. 20, wherein the foot 186 of the E-beam 178 can engage a groove extending along the bottom surface of the channel 198 along the length of the slot 189, the middle pin 184 can engage the top surface of the cartridge tray 196 along the length of the longitudinal slot 197, and the upper pin 180 can engage the anvil 306. In this instance, the E-beam 178 can separate or limit the relative movement between the anvil 306 and the staple cartridge 304 as the firing bar 172 moves distally to fire the staples from the staple cartridge 304 and/or incise tissue trapped between the anvil 306 and the staple cartridge 304. The firing bar 172 and the E-beam 178 can then be retracted proximally, allowing the anvil 306 to open to release the two stapled and severed tissue portions (not shown).

Having now generally described the surgical instrument 10, the various power/electronic components of the surgical instrument 10 will be described in detail below. Turning now to fig. 21A-21B, one embodiment of a segmented circuit 2000 comprising a plurality of circuit segments 2002a-2002g is shown. The segmented circuit 2000, which includes a plurality of circuit segments 2002a-2002g, is configured to control an energized surgical instrument, such as, but not limited to, the surgical instrument 10 shown in FIGS. 1-18A. The plurality of circuit segments 2002a-2002g are configured to control one or more operations of the powered surgical instrument 10. The safety processor segment 2002a (segment 1) includes a safety processor 2004. The primary processor segment 2002b (segment 2) includes a primary processor 2006. The safety processor 2004 and/or the primary processor 2006 are configured to interact with one or more additional circuit segments 2002c-2002g to control the operation of the powered surgical instrument 10. The primary processor 2006 includes a plurality of input devices coupled to, for example, one or more circuit segments 2002c-2002g, a battery 2008, and/or a plurality of switches 2058 a-2070. The segmented circuit 2000 may be implemented by any suitable circuitry, such as a Printed Circuit Board Assembly (PCBA) within the powered surgical instrument 10. It is to be understood that the term "processor" as used herein includes any kind of microprocessor, microcontroller, or other basic computing device that combines the functions of a computer's Central Processing Unit (CPU) onto one integrated circuit or at most several integrated circuits. A processor is a multipurpose programmable device that receives digital data as input, processes the input according to instructions stored in its memory, and then provides the result as output. The processor has internal memory and is therefore an example of sequential digital logic. The operands of the processor are numbers and symbols represented in a binary numerical system.

In one embodiment, the primary processor 2006 may be any type of single or multi-core processor, such as those known under the trade name ARM Cortex, manufactured by Texas Instruments. In one embodiment, the safety processor 2004 may be a safety microcontroller platform comprising two microcontroller-based families, such as TMS570 and RM4x, known under the trade name Hercules ARM Cortex R4, also produced by Texas Instruments. However, other suitable alternatives for the microcontroller and the secure processor may be employed without limitation. In one embodiment, the safety processor 2004 may be specifically configured for IEC 61508 and ISO 26262 safety critical applications, among others, to provide advanced integrated safety features in delivering quantifiable performance, connectivity, and storage options.

In some cases, the primary processor 2006 may be, for example, LM4F230H5QR, available from Texas Instruments. In at least one example, the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F processor core that includes: 256KB of on-chip memory of Single cycle flash memory or other non-volatile memory (up to 40MHz), prefetch buffers to improve performance beyond 40MHz, 32KB of Single cycle SRAM, load with

Internal ROM of software, EEPROM of 2KB, one or more PWM modules, one or more QEI analog, one or more 12-bit ADC with 12 analog input channels, and other features readily available for production data sheet. Other processors may be readily substituted, and the disclosure should not be limited in this context.

In one embodiment, the segmented circuit 2000 includes an acceleration segment 2002c (segment 3). The acceleration segment 2002c includes an acceleration sensor 2022. The acceleration sensor 2022 may include, for example, an accelerometer. The acceleration sensor 2022 is configured to detect motion or acceleration of the powered surgical instrument 10. In some embodiments, input from the acceleration sensor 2022 is used to, for example, transition to and from sleep mode, identify the orientation of the powered surgical instrument, and/or identify when the surgical instrument has been dropped. In some embodiments, the acceleration segment 2002c is coupled to the safety processor 2004 and/or the primary processor 2006.

In one embodiment, the segmentation circuit 2000 includes a display segment 2002d (segment 4). The display segment 2002d includes a display connector 2024 coupled to the primary processor 2006. The display connector 2024 couples the primary processor 2006 to a display 2028 through one or more display driver integrated circuits 2026. The display driver integrated circuit 2026 may be integrated with the display 2028 and/or may be located separately from the display 2028. The display 2028 can include any suitable display, such as an Organic Light Emitting Diode (OLED) display, a Liquid Crystal Display (LCD), and/or any other suitable display. In some embodiments, the display segment 2002d is coupled to the safety processor 2004.

In some embodiments, segmented circuit 2000 includes a shaft segment 2002e (segment 5). The shaft segment 2002e comprises one or more controls for coupling to a shaft 2004 of the surgical instrument 10, and/or one or more controls for coupling to an end effector 2006 of the shaft 2004. The shaft segment 2002e comprises a shaft connector 2030 configured to couple the primary processor 2006 to the shaft PCBA 2031. The shaft PCBA 2031 includes a first articulation switch 2036, a second articulation switch 2032, and a shaft PCBA EEPROM 2034. In some embodiments, the shaft PCBA EEPROM 2034 comprises one or more parameters, routines, and/or programs that are specific to the shaft 2004 and/or the shaft PCBA 2031. The shaft PCBA 2031 may be coupled to the shaft 2004 and/or integrally formed with the surgical instrument 10. In some embodiments, the shaft segment 2002e comprises a second shaft EEPROM 2038. The second shaft EEPROM 2038 includes a plurality of algorithms, routines, parameters, and/or other data corresponding to one or more shafts 2004 and/or end effectors 2006 that may interface with the powered surgical instrument 10.

In some embodiments, segmentation circuit 2000 includes position encoder segment 2002f (segment 6). The position encoder segment 2002f includes one or more magnetic rotary position encoders 2040a-2040 b. The one or more magnetic rotary position encoders 2040a-2040b are configured to identify the rotary position of the motor 2048, the shaft 2004, and/or the end effector 2006 of the surgical instrument 10. In some embodiments, the magnetic rotary position encoders 2040a-2040b may be coupled to the safety processor 2004 and/or the primary processor 2006.

In some embodiments, segmented circuit 2000 includes motor segment 2002g (segment 7). The motor segment 2002g includes a motor 2048 configured to control one or more motions of the powered surgical instrument 10. The motor 2048 is coupled to the primary processor 2006 by an H-bridge driver 2042 and one or more H-bridge Field Effect Transistors (FETs) 2044. The H-bridge FET 2044 is coupled to the safety processor 2004. A motor current sensor 2046 is coupled in series with the motor 2048 for measuring the current draw of the motor 2048. The motor current sensor 2046 is in signal communication with the primary processor 2006 and/or the safety processor 2004. In some embodiments, the motor 2048 is coupled to a motor electromagnetic interference (EMI) filter 2050.

Segmented circuit 2000 includes power segment 2002h (segment 8). The battery 2008 is coupled to the safety processor 2004, the primary processor 2006, and one or more of the additional circuit segments 2002c-2002 g. The battery 2008 is coupled to the segmented circuit 2000 by a battery connector 2010 and a current sensor 2012. The current sensor 2012 is configured to measure the total current consumption of the segmented circuit 2000. In some embodiments, one or more voltage converters 2014a, 2014b, 2016 are configured to provide predetermined voltage values to one or more circuit segments 2002a-2002 g. For example, in some embodiments, the segmented circuit 2000 may include 3.3V voltage converters 2014a-2014b and/or 5V voltage converters 2016. The boost converter 2018 is configured to be capable of providing a boost voltage up to a predetermined amount, such as up to 13V. The boost converter 2018 is configured to provide additional voltage and/or current during power intensive operations and to prevent reduced voltage or low power conditions.

In some embodiments, the safety segment 2002a includes a motor power interrupt 2020. The motor power interrupt 2020 is coupled between the power segment 2002h and the motor segment 2002 g. The safety segment 2002a is configured to interrupt power to the motor segment 2002g when the safety processor 2004 and/or the primary processor 2006 detect an error or fault condition, as discussed in greater detail herein. Although the circuit segments 2002a-2002g are shown with all components in the circuit segments 2002a-2002h physically located proximate, one skilled in the art will recognize that the circuit segments 2002a-2002h may include other components that are physically and/or electrically separate from the components of the same circuit segments 2002a-2002 g. In some embodiments, one or more components may be shared by two or more circuit segments 2002a-2002 g.

In some embodiments, a plurality of switches 2056 and 2070 are coupled to the safety processor 2004 and/or the primary processor 2006. The plurality of switches 2056 and 2070 may be configured to control one or more operations of the surgical instrument 10, to control one or more operations of the segmented circuit 2000, and/or to indicate a status of the surgical instrument 10. For example, the panic door switch 2056 is configured to indicate the status of the panic door. A plurality of articulation switches (such as a left articulation switch 2058a, a left right articulation switch 2060a, a left center articulation switch 2062a, a right left articulation switch 2058b, a right center articulation switch 2060b, and a right center articulation switch 2062b) are configured to control articulation of the shaft 2004 and/or the end effector 2006. The left switch 2064a and the right switch 2064b are coupled to the primary processor 2006. In some embodiments, left switches (including a left articulation switch 2058a, a left right articulation switch 2060a, a left center articulation switch 2062a, and a left reversing switch 2064a) are coupled to the primary processor 2006 by a left flex connector 2072 a. The right switches (including right left articulation switch 2058b, right articulation switch 2060b, right center articulation switch 2062b, and right reversing switch 2064b) are coupled to the primary processor 2006 by a right flex connector 2072 b. In some embodiments, a firing switch 2066, a clamp release switch 2068, and a shaft engagement switch 2070 are coupled to the primary processor 2006.

The plurality of switches 2056 and 2070 may comprise, for example, a plurality of handle controls mounted to the handle of the surgical instrument 10, a plurality of indicator switches, and/or any combination thereof. In various embodiments, the plurality of switches 2056 and 2070 allow the surgeon to manipulate the surgical instrument, provide feedback to the segmented circuit 2000 regarding the position and/or operation of the surgical instrument, and/or indicate unsafe operation of the surgical instrument 10. In some embodiments, additional or fewer switches may be coupled to the segmented circuit 2000, and one or more of the switches 2056 and 2070 may be combined into a single switch, and/or expanded into multiple switches. For example, in one embodiment, one or more of the left and/or right articulation switches 2058a-2064b may be combined into a single multi-position switch.

In one embodiment, the safety processor 2004 is configured to implement a watchdog function, among other safety operations. The safety processor 2004 and the primary processor 2006 of the segmented circuit 2000 are in signal communication. The microprocessor live heartbeat signal is provided at output 2096. The acceleration segment 2002c includes an accelerometer 2022 configured to monitor movement of the surgical instrument 10. In various embodiments, the accelerometer 2022 may be a single axis, dual axis, or triple axis accelerometer. The accelerometer 2022 may be used to measure suitable acceleration, which is not necessarily coordinate acceleration (rate of change of velocity). Instead, the accelerometer observes the acceleration associated with the weight phenomenon experienced by the test mass when the frame of reference of the accelerometer 2022 is stationary. For example, an accelerometer 2022 stationary on the surface of the earth will measure a vertical upward (gravitational) acceleration g of 9.8m/s due to its weight ². Another type of acceleration that the accelerometer 2022 can measure is gravitational acceleration. In various other embodiments, the accelerometer 2022 may comprise a single axis, dual axis, or triple axis accelerometer. Further, the acceleration segment 2002c may include one or more inertial sensors to detect and measure acceleration, tilt, and jerkShock, vibration, rotation, and multiple degrees of freedom (DoF). Suitable inertial sensors may include accelerometers (single, dual or triple axis), magnetometers for measuring spatial magnetic fields, such as the earth's magnetic field, and/or gyroscopes for measuring angular velocity.

In one embodiment, the safety processor 2004 is configured to implement a watchdog function for one or more circuit segments 2002c-2002h (such as motor segment 2002 g). In this regard, the safety processor 2004 employs a watchdog function to detect and recover from a failure of the primary processor 2006. During normal operation, the safety processor 2004 monitors the primary processor 2004 for hardware faults or program errors and initiates one or more corrective actions. Corrective action may include placing the primary processor 2006 in a safe state and resuming normal system operation. In one embodiment, the safety processor 2004 is coupled to at least a first sensor. The first sensor measures a first property of the surgical instrument 10. In some embodiments, the safety processor 2004 is configured to compare the measured property of the surgical instrument 10 to a predetermined value. For example, in one embodiment, the motor sensor 2040a is coupled to the safety processor 2004. The motor sensors 2040a provide speed and position information of the motor to the safety processor 2004. The safety processor 2004 monitors the motor sensor 2040a and compares the value to a maximum speed and/or position value, and prevents operation of the motor 2048 if the value is above a predetermined value. In some embodiments, the predetermined values are calculated based on real-time speed and/or position of the motor 2048, calculated from values provided by the second motor sensor 2040b in communication with the primary processor 2006, and/or provided to the safety processor 2004 from, for example, a memory module coupled to the safety processor 2004.

In some embodiments, the second sensor is coupled to the primary processor 2006. The second sensor is configured to measure the first physical property. The safety processor 2004 and the primary processor 2006 are configured to provide signals indicative of the value of the first sensor and the value of the second sensor, respectively. When the safety processor 2004 or the primary processor 2006 indicates a value outside of an acceptable range, the segmented circuit 2000 prevents operation of at least one of the circuit segments 2002c-2002h, such as the motor segment 2002 g. For example, in the embodiment shown in fig. 21A-21B, the safety processor 2004 is coupled to a first motor position sensor 2040a and the primary processor 2006 is coupled to a second motor position sensor 2040B. The motor position sensors 2040a, 2040b may comprise any suitable motor position sensor, such as a magnetic angular rotational input device having sine and cosine outputs. The motor position sensors 2040a, 2040b provide respective signals indicative of the position of the motor 2048 to the safety processor 2004 and the primary processor 2006.

The safety processor 2004 and the primary processor 2006 generate activation signals when the values of the first motor sensor 2040a and the second motor sensor 2040b are within predetermined ranges. When the primary processor 2006 or the safety processor 2004 detects a value outside of a predetermined range, the activation signal is terminated, whereupon operation of at least one of the circuit segments 2002c-2002h (such as the motor segment 2002g) is interrupted and/or prevented. For example, in some embodiments, the activation signal from the primary processor 2006 and the activation signal from the safety processor 2004 are coupled to an and gate. The and gate is coupled to a motor power switch 2020. When the activation signals from both the safety processor 2004 and the primary processor 2006 are high (indicating that the values of the motor sensors 2040a, 2040b are within a predetermined range), the and gate maintains the motor power switch 2020 in a closed or open position. When either of the motor sensors 2040a, 2040b detects a value outside of a predetermined range, then the activation signals from the motor sensors 2040a, 2040b are set low and the output of the and gate is also set low, opening the motor power switch 2020. In some embodiments, the value of the first sensor 2040a is compared to the value of the second sensor 2040b, for example, by the safety processor 2004 and/or the primary processor 2006. When the value of the first sensor is different from the value of the second sensor, the safety processor 2004 and/or the primary processor 2006 may prevent operation of the motor segment 2002 g.

In some embodiments, the safety processor 2004 receives a signal indicative of the value of the second sensor 2040b and compares the value of the second sensor to the value of the first sensor. For example, in one embodiment, the safety processor 2004 is coupled directly to the first motor sensor 2040 a. The second motor sensor 2040b is coupled to the primary processor 2006 (which provides the value of the second motor sensor 2040b to the safety processor 2004) and/or directly to the safety processor 2004. The safety processor 2004 compares the value of the first motor sensor 2040 with the value of the second motor sensor 2040 b. When the safety processor 2004 detects a mismatch between the first motor sensor 2040a and the second motor sensor 2040b, the safety processor 2004 may interrupt operation of the motor segment 2002g, for example, by cutting power to the motor segment 2002 g.

In some embodiments, the safety processor 2004 and/or the primary processor 2006 are coupled to a first sensor 2040a configured to measure a first property of the surgical instrument and a second sensor 2040b configured to measure a second property of the surgical instrument. The first property and the second property comprise a predetermined relationship when the surgical instrument is operating normally. The safety processor 2004 monitors the first property and the second property. A fault is detected when the value of the first property and/or the value of the second property is not in accordance with the predetermined relationship. In the event of a failure, the safety processor 2004 takes at least one action, such as blocking operation of at least one of the circuit segments, performing a predetermined operation, and/or resetting the primary processor 2006. For example, the safety processor 2004 may open the motor power switch 2020 to cut power to the motor circuit segment 2002g when a fault is detected.

In one embodiment, the safety processor 2004 is configured to execute a separate control algorithm. In operation, the safety processor 2004 monitors the segmented circuit 2000 and is configured to independently control and/or override signals from other circuit components, such as the primary processor 2006. The safety processor 2004 may execute preprogrammed algorithms and/or may be updated or programmed online during operation based on one or more actions and/or positions of the surgical instrument 10. For example, in one embodiment, the safety processor 2004 is reprogrammed with new parameters and/or safety algorithms each time a new shaft and/or end effector is coupled to the surgical instrument 10. In some embodiments, one or more safety values stored by the safety processor 2004 are copied by the primary processor 2006. Bidirectional error detection is performed to ensure that the values and/or parameters stored by the processor 2004 or 2006 are correct.

In some embodiments, the safety processor 2004 and the primary processor 2006 implement redundant safety checks. The safety processor 2004 and the primary processor 2006 provide periodic signals indicating normal operation. For example, during operation, the safety processor 2004 may indicate to the primary processor 2006 that the safety processor 2004 is executing code and operating normally. The primary processor 2006 may likewise indicate to the safety processor 2004 that the primary processor 2006 is executing code and operating normally. In some embodiments, the safety processor 2004 and the primary processor 2006 communicate at predetermined intervals. The predetermined interval may be constant or may vary depending on the state of the circuit and/or the operation of the surgical instrument 10.

Fig. 22 illustrates one example of a power assembly 2100 including a usage cycle circuit 2102 configured to monitor a usage cycle count of the power assembly 2100. The power assembly 2100 may be coupled to a surgical instrument 2110. The usage cycle circuit 2102 includes a processor 2104 and a usage indicator 2106. The use indicator 2106 is configured to provide a signal to the processor 2104 to indicate use of the battery pack 2100 and/or a surgical instrument 2110 coupled to the power assembly 2100. "use case" may include any suitable action, condition, and/or parameter, for example, changing modular components of the surgical instrument 2110, deploying or firing disposable components coupled to the surgical instrument 2110, delivering electrosurgical energy from the surgical instrument 2110, repairing the surgical instrument 2110 and/or the power assembly 2100, exchanging the power assembly 2100, recharging the power assembly 2100, and/or exceeding safety limits of the surgical instrument 2110 and/or the battery pack 2100.

In some cases, the usage cycle or usage is defined by one or more power component 2100 parameters. For example, in one case, when power assembly 2100 is at a fully charged level, using a cycle includes using greater than 5% of the total energy available from power assembly 2100. In another case, the usage cycle includes a continuous energy consumption from the power assembly 2100 that exceeds a predetermined time limit. For example, a usage cycle may correspond to five minutes of continuous and/or total energy consumption from power assembly 2100. In some cases, the power assembly 2100 includes a usage cycling circuit 2102 that presents a continuous power consumption to maintain one or more components of the usage cycling circuit 2102, such as the usage indicator 2106 and/or the counter 2108, in an operational state.

Processor 2104 maintains a usage cycle count. The usage cycle count indicates the number of uses of the power assembly 2100 and/or surgical instrument 2110 detected by the usage indicator 2106. Processor 2104 may increase and/or decrease a usage cycle count based on input from usage indicator 2106. The cycle count is used to control one or more operations of the power assembly 2100 and/or the surgical instrument 2110. For example, in some cases, power component 2100 is disabled when the usage cycle count exceeds a predetermined usage limit. Although the cases described herein are discussed with respect to increasing the usage cycle count beyond a predetermined usage limit, those skilled in the art will recognize that the usage cycle count may begin at some predetermined amount and may be decreased by processor 2104. In this case, the processor 2104 enables and/or prevents one or more operations of the power assembly 2100 when the usage cycle count falls below a predetermined usage limit.

The usage cycle count is maintained by counter 2108. Counter 2108 includes any suitable circuitry, such as a memory module, an analog counter, and/or any circuitry configured to maintain a usage cycle count. In some cases, the counter 2108 is integrally formed with the processor 2104. In other cases, counter 2108 comprises a separate component, such as a solid state memory module. In some cases, the usage cycle count is provided to a remote system, such as a central database. The usage cycle count is transmitted to the remote system by the communication module 2112. The communication module 2112 is configured to be capable of using any suitable communication medium, e.g., wired and/or wireless communication. In some cases, the communication module 2112 is configured to receive one or more instructions, such as a control signal, from a remote system when the usage cycle count exceeds a predetermined usage limit.

In some cases, the usage indicator 2106 is configured to monitor the number of modular components used with the surgical instrument 2110 coupled to the power assembly 2100. The modular components may include, for example, a modular shaft, a modular end effector, and/or any other modular component. In some instances, the usage indicator 2106 monitors usage of one or more disposable components, such as insertion and/or deployment of a staple cartridge within an end effector coupled to the surgical instrument 2110. The usage indicator 2106 includes one or more sensors for detecting the exchange of one or more modular and/or disposable components of the surgical instrument 2110.

In some cases, use indicator 2106 is configured to monitor a single patient surgical procedure performed when power assembly 2100 is installed. For example, the usage indicator 2106 may be configured to monitor the firing of the surgical instrument 2110 when the power assembly 2100 is coupled to the surgical instrument 2110. Firing may correspond to deployment of a staple cartridge, application of electrosurgical energy, and/or any other suitable surgical event. The usage indicator 2106 may include one or more circuits for measuring the number of firings when the power assembly 2100 has been installed. When a single patient procedure is performed, the use indicator 2106 provides a signal to the processor 2104, and the processor 2104 increments a use cycle count.

In some cases, the usage indicator 2106 includes circuitry configured to monitor one or more parameters of the power source 2114 (e.g., current drawn from the power source 2114). The one or more parameters of the power source 2114 correspond to one or more operations that may be performed by the surgical instrument 2110, such as, for example, cutting and stapling operations. The usage indicator 2106 provides one or more parameters to the processor 2104, which increases the usage cycle count when the one or more parameters indicate that the procedure has been performed.

In some cases, the usage indicator 2106 includes a timing circuit configured to increase a usage cycle count after a predetermined period of time. The predetermined time period corresponds to a single patient procedure time, i.e., the time required for the operator to perform a procedure (e.g., a cutting and stapling procedure). When the power assembly 2100 is coupled to the surgical instrument 2110, the processor 2104 polls the use indicator 2106 to determine whether the single patient procedure time has ended. If the predetermined time period has elapsed, the processor 2104 increments a usage cycle count. After incrementing the usage cycle count, processor 2104 resets the timing circuitry of user indicator 2106.

In some cases, the use indicator 2106 includes a time constant that approximates the time of a single patient procedure. In one embodiment, the usage cycle circuit 2102 includes a resistor-capacitor (RC) timing circuit 2506. The RC timing circuit includes a time constant defined by a resistor-capacitor pair. The time constant is defined by the values of the resistor and the capacitor. In one embodiment, the usage cycle circuit 2552 includes a rechargeable battery and a clock. When the power assembly 2100 is installed in a surgical instrument, the rechargeable battery is charged by the power source. The rechargeable battery includes sufficient power to run the clock for at least a single patient procedure time. The clock may include a real-time clock, a processor configured to enable timing functions, or any other suitable timing circuitry.

Referring back to fig. 2, in some cases, usage indicator 2106 includes a sensor configured to monitor one or more environmental conditions experienced by power assembly 2100. For example, usage indicator 2106 may include an accelerometer. The accelerometer is configured to monitor acceleration of the power assembly 2100. The power assembly 2100 has a maximum acceleration tolerance. An example of acceleration exceeding a predetermined threshold value is that power component 2100 has been dropped. When the usage indicator 2106 detects that the acceleration exceeds the maximum acceleration tolerance, the processor 2104 increments a usage cycle count. In some cases, usage indicator 2106 includes a moisture sensor. The moisture sensor is configured to indicate when the power assembly 2100 has been exposed to moisture. The moisture sensor may include, for example, an immersion sensor configured to indicate when the power assembly 2100 has been fully immersed in the cleaning fluid, a moisture sensor configured to indicate when moisture contacts the power assembly 2100 during use, and/or any other suitable moisture sensor.

In some cases, usage indicator 2106 comprises a chemical contact sensor. The chemical contact sensor is configured to indicate when the power assembly 2100 has been in contact with a hazardous and/or dangerous chemical. For example, during sterilization, unsuitable chemicals may be used that cause degradation of the power assembly 2100. When the use indicator 2106 detects an unsuitable chemical, the processor 2104 increments a use cycle count.

In some cases, the usage cycling circuit 2102 is configured to monitor the number of repair cycles experienced by the power assembly 2100. The repair cycle may include, for example, a cleaning cycle, a sterilization cycle, a charging cycle, routine and/or preventive maintenance, and/or any other suitable repair cycle. The usage indicator 2106 is configured to detect a repair cycle. For example, the usage indicator 2106 may include a moisture sensor to detect cleaning and/or sterilization cycles. In some cases, the number of repair cycles experienced by the power assembly 2100 is monitored using the cycling circuit 2102 and the power assembly 2100 is disabled after the number of repair cycles exceeds a predetermined threshold.

The usage cycle circuit 2102 may be configured to monitor the number of power assembly 2100 exchanges. The usage cycle circuit 2102 increments a usage cycle count each time the power assembly 2100 is swapped. When the maximum number of exchanges is exceeded, the power assembly 2100 and/or the surgical instrument 2110 are locked out using the cycling circuit 2102. In some cases, when the power assembly 2100 is coupled to the surgical instrument 2110, the usage cycle circuit 2102 identifies the serial number of the power assembly 2100 and locks the power assembly 2100 such that the power assembly 2100 can only be used with the surgical instrument 2110. In some instances, the usage cycle circuit 2102 increases the usage cycle each time the power assembly 2100 is removed from and/or coupled to the surgical instrument 2110.

In some cases, the usage cycle count corresponds to disinfection of the power assembly 2100. The usage indicator 2106 comprises a sensor configured to detect one or more parameters of the sterilization cycle (e.g., a temperature parameter, a chemical parameter, a moisture parameter, and/or any other suitable parameter). When the sterilization parameters are detected, the processor 2104 increments a usage cycle count. After a predetermined number of sterilizations, the power assembly 2100 is deactivated using the cycling circuit 2102. In some cases, the usage cycle circuit 2102 is reset during a sterilization cycle, a voltage sensor, and/or any suitable sensor detection recharge cycle. When a repair loop is detected, the processor 2104 increments a usage loop count. When a sterilization cycle is detected, the usage cycle circuit 2102 is disabled. The usage cycle circuit 2102 is reactivated and/or reset when the power assembly 2100 is coupled to the surgical instrument 2110. In some cases, the usage indicator includes a zero power indicator. The zero power indicator changes state during the sterilization cycle and is checked by the processor 2104 when the power assembly 2100 is coupled to the surgical instrument 2110. When the zero power indicator indicates that a sterilization cycle has occurred, processor 2104 increments a usage cycle count.

Counter 2108 keeps the usage cycle count. In some cases, counter 2108 comprises a non-volatile memory module. Whenever a usage cycle is detected, the processor 2104 increments a usage cycle count stored in the non-volatile memory module. The memory module is accessible by the processor 2104 and/or control circuitry (e.g., control circuitry 200). When the usage cycle count exceeds a predetermined threshold, the processor 2104 disables the power component 2100. In some cases, the usage cycle count is maintained by a plurality of circuit components. For example, in one case, the counter 2108 comprises a bank of resistors (or fuses). After each use of the power assembly 2100, the resistors (or fuses) may be blown into an open position, thereby changing the resistance of the resistor bank. The power assembly 2100 and/or surgical instrument 2110 reads the remaining resistance. When the last resistor of the resistor bank is burned out, the resistor bank has a predetermined resistance (e.g., corresponding to infinite resistance of an open circuit), which indicates that the power assembly 2100 has reached its limit of use. In some cases, the resistance of the resistor bank is used to derive the remaining number of uses.

In some cases, the usage cycle circuit 2102 prevents further use of the power assembly 2100 and/or the surgical instrument 2110 when the usage cycle count exceeds a predetermined usage limit. In one case, the usage cycle count associated with the power assembly 2100 is provided to the operator, for example, using a screen integrally formed with the surgical instrument 2110. The surgical instrument 2110 provides an indication to the operator that the usage cycle count has exceeded a predetermined limit of the power assembly 2100 and prevents further operation of the surgical instrument 2110.

In some cases, the usage cycle circuit 2102 is configured to physically prevent operation thereof when a predetermined usage limit is reached. For example, the power assembly 2100 may include a shroud configured to be deployed over the contacts of the power assembly 2100 when the usage cycle count exceeds a predetermined usage limit. The shroud prevents recharging and use of power assembly 2100 by covering the electrical connections of power assembly 2100.

In some cases, the usage cycle circuit 2102 is at least partially located within the surgical instrument 2110 and is configured to maintain a usage cycle count of the surgical instrument 2110. FIG. 22 illustrates, in phantom, one or more components of a usage cycling circuit 2102 within a surgical instrument 2110 and illustrates an alternative positioning of the usage cycling circuit 2102. The usage cycle circuit 2102 deactivates and/or prevents operation of the surgical instrument 2110 when a predetermined usage limit of the surgical instrument 2110 is exceeded. When the use indicator 2106 detects a particular event and/or need (e.g., firing of the surgical instrument 2110, a predetermined time period corresponding to a single patient procedure time), the use cycle circuit 2102 increments the use cycle count according to one or more motor parameters of the surgical instrument 2110 in response to the system diagnostic indicating that one or more predetermined thresholds have been reached and/or any other suitable need has been met. As discussed above, in some cases, the use indicator 2106 includes a timing circuit corresponding to a single patient procedure time. In other instances, the usage indicator 2106 includes one or more sensors configured to detect particular events and/or conditions of the surgical instrument 2110.

In some cases, the usage cycle circuit 2102 is configured to prevent use of the surgical instrument 2110 after a predetermined usage limit is reached. In some cases, the surgical instrument 2110 includes a visual indicator to indicate when a predetermined use limit has been reached and/or exceeded. For example, a marking (such as a red marking) may be ejected from the surgical instrument 2110 (such as from the handle) to provide a visual indication to the operator that the surgical instrument 2110 has exceeded a predetermined use limit. As another example, the usage cycle circuit 2102 can be coupled to a display that is integrally formed with the surgical instrument 2110. The usage cycle circuit 2102 displays information indicating that a predetermined usage limit has been exceeded. The surgical instrument 2110 may provide an audible indication to the operator that a predetermined usage limit has been exceeded. For example, in one instance, when a predetermined usage limit is exceeded, the surgical instrument 2110 emits an audible tone and the power assembly 2100 is then removed from the surgical instrument 2110. The audible tone indicates the last use of the surgical instrument 2110 and indicates that the surgical instrument 2110 should be discarded or repaired.

In some cases, the usage cycle circuit 2102 is configured to transmit the usage cycle count of the surgical instrument 2110 to a remote location, e.g., a central database. The usage cycle circuit 2102 includes a communication module 2112 configured to transmit the usage cycle count to a remote location. The communication module 2112 may utilize any suitable communication system, such as a wired and/or wireless communication system. The remote location may include a central database configured to maintain usage information. In some cases, when the power assembly 2100 is coupled to the surgical instrument 2110, the power assembly 2100 records the serial number of the surgical instrument 2110. For example, when the power assembly 2100 is coupled to a charger, the serial number is transmitted to a central database. In some cases, the central database maintains a count corresponding to each use of the surgical instrument 2110. For example, each time the surgical instrument 2110 is used, a barcode associated with the surgical instrument 2110 may be scanned. When the usage count exceeds a predetermined usage limit, the central database provides a signal to the surgical instrument 2110 indicating that the surgical instrument 2110 should be discarded.

The surgical instrument 2110 can be configured to lock out and/or prevent operation of the surgical instrument 2110 when the usage cycle count exceeds a predetermined usage limit. In some cases, the surgical instrument 2110 comprises a disposable instrument and is discarded after the usage cycle count exceeds a predetermined usage limit. In other instances, the surgical instrument 2110 comprises a reusable surgical instrument that can be reconditioned after a usage cycle count exceeds a predetermined usage limit. The surgical instrument 2110 initiates reversible lockout after a predetermined limit of use is reached. The technician repairs the surgical instrument 2110 and releases the latch, for example, using a technical key configured to reset the usage cycle circuit 2102.

In some embodiments, the segmented circuit 2000 is configured to be sequentially enabled. Error checking is performed by each circuit segment 2002a-2002g before power is applied to the next circuit segment 2002a-2002g in the sequence. Figure 23 illustrates one embodiment of a process for sequentially powering up segmented circuits 2270, e.g., segmented circuit 2000. When the battery 2008 is coupled to the segmented circuit 2000, the safety processor 2004 powers up 2272. The safety processor 2004 performs an error self test 2274. When an error is detected 2276a, the secure processor stops powering the segmented circuit 2000 and generates an error code 2278 a. When no error is detected 2276b, the safety processor 2004 begins to power up the primary processor 2006 2278 b. The primary processor 2006 performs an error self-check. When no errors are detected, the primary processor 2006 begins sequentially powering up 2278b each of the remaining circuit segments. The primary processor 2006 powers up and checks for errors for each circuit segment. When no error is detected, the next circuit segment is energized 2278 b. When an error is detected, the safety processor 2004 and/or the primary processor stops energizing the current segment and generates an error 2278 a. Sequential activation continues until the circuit segments 2002a-2002g have all been energized. In some embodiments, the segmented circuit 2000 transitions from the sleep mode after a similar sequential power-up process 11250.

Fig. 24 illustrates one embodiment of a power segment 2302 that includes a plurality of daisy-chained power converters 2314, 2316, 2318. The power segment 2302 includes a battery 2308. The battery 2308 is configured to provide a source voltage, such as 12V. A current sensor 2312 is coupled to the battery 2308 to monitor the current draw of the segmented circuit and/or one or more circuit segments. The current sensor 2312 is coupled to an FET switch 2313. The battery 2308 is coupled to one or more voltage converters 2309, 2314, 2316. The always-on converter 2309 provides a constant voltage to one or more circuit components, such as the motion sensor 2322. The always-on converter 2309 includes, for example, a 3.3V converter. The always-on converter 2309 may provide a constant voltage to additional circuit components, such as a safety processor (not shown). The battery 2308 is coupled to a boost converter 2318. The boost converter 2318 is configured to provide a boosted voltage greater than that provided by the battery 2308. For example, in the illustrated embodiment, the battery 2308 provides 12V. The boost converter 2318 is configured to boost the voltage to 13V. The boost converter 2318 is configured to maintain a minimum voltage during operation of a surgical instrument (e.g., the surgical instrument 10 shown in fig. 69-71). Operation of the motor may cause the power provided to the primary processor 2306 to drop below a minimum threshold and create a voltage drop or reset condition in the primary processor 2306. The boost converter 2318 ensures that sufficient power is available to the primary processor 2306 and/or other circuit components, such as the motor controller 2343, during operation of the surgical instrument 10. In some embodiments, the boost converter 2318 is coupled directly to one or more circuit components, such as an OLED display 2388.

The boost converter 2318 is coupled to one or more buck converters to provide a voltage below the boost voltage level. The first voltage converter 2316 is coupled to the boost converter 2318 and provides a reduced voltage to one or more circuit components. In the illustrated embodiment, the first voltage converter 2316 provides a voltage of 5V. The first voltage converter 2316 is coupled to a rotary position encoder 2340. The FET switch 2317 is coupled between the first voltage converter 2316 and the rotary position encoder 2340. The FET switch 2317 is controlled by the processor 2306. The processor 2306 opens the FET switch 2317 to deactivate the position encoder 2340, for example, during power intensive operations. The first voltage converter 2316 is coupled to a second voltage converter 2314, which is configured to provide a second reduced voltage. The second reduced voltage includes, for example, a voltage of 3.3V. The second voltage converter 2314 is coupled to the processor 2306. In some embodiments, the boost converter 2318, the first voltage converter 2316, and the second voltage converter 2314 are coupled in a daisy-chain configuration. The daisy-chain configuration allows the use of smaller and more efficient converters for generating voltage levels lower than the boosted voltage level. However, these embodiments are not limited to the particular voltage ranges described in the context of this specification.

Fig. 25 illustrates one embodiment of a segmented circuit 2400 configured to maximize power available to a circuit and/or power intensive functions. The segmented circuit 2400 includes a battery 2408. The battery 2408 is configured to provide a source voltage, such as 12V. The source voltage is provided to a plurality of voltage converters 2409, 2418. The always-on voltage converter 2409 provides a constant voltage to one or more circuit components, such as the motion sensor 2422 and the safety processor 2404. The always-on voltage converter 2409 is coupled directly to the battery 2408. The always-on voltage converter 2409 provides a voltage of, for example, 3.3V. However, these embodiments are not limited to the particular voltage ranges described in the context of this specification.

The segmented circuit 2400 includes a boost converter 2418. The boost converter 2418 provides a boosted voltage that is greater than the source voltage (e.g., 13V) provided by the battery 2408. The boost converter 2418 provides a boosted voltage directly to one or more circuit components, such as the OLED display 2488 and the motor controller 2443. By coupling the OLED display 2488 directly to the boost converter 2418, the segmented circuit 2400 eliminates the need for a power converter dedicated to the OLED display 2488. The boost converter 2418 provides a boosted voltage to the motor controller 2443 and the motor 2448 during one or more power intensive operations of the motor 2448, such as a cutting operation. The boost converter 2418 is coupled to the buck converter 2416. The buck converter 2416 is configured to provide a voltage (e.g., 5V) lower than the boosted voltage to one or more circuit components. The buck converter 2416 is coupled to, for example, a FET switch 2451 and a position encoder 2440. The FET switch 2451 is coupled to the main processor 2406. When the segmented circuit 2400 transitions to the sleep mode, and/or during power intensive functions requiring additional voltage to be delivered to the motor 2448, the main processor 2406 turns off the FET switch 2451. Opening the FET switch 2451 deactivates the position encoder 2440 and eliminates power consumption by the position encoder 2440. However, these embodiments are not limited to the particular voltage ranges described in the context of this specification.

The buck converter 2416 is coupled to the linear converter 2414. The linear converter 2414 is configured to provide a voltage of, for example, 3.3V. The linear converter 2414 is coupled to the primary processor 2406. The linear converter 2414 provides an operating voltage to the main processor 2406. The linear converter 2414 may be coupled to one or more additional circuit components. However, these embodiments are not limited to the particular voltage ranges described in the context of this specification.

The segmented circuit 2400 includes an emergency switch 2456. The panic switch 2456 is coupled to a panic door on the surgical instrument 10. Emergency switch 2456 and safety processor 2404 are coupled to an and gate 2419. And gate 2419 provides an input to FET switch 2413. When the panic switch 2456 detects a voltage drop condition, the panic switch 2456 provides a panic close signal to the and gate 2419. When security processor 2404 detects an unsafe condition, e.g., due to a sensor mismatch, security processor 2404 provides a close signal to and gate 2419. In some embodiments, both the emergency shutdown signal and the shutdown signal are high during normal operation and low when a reduced voltage condition or unsafe condition is detected. When the output of and gate 2419 is low, FET switch 2413 is open and operation of motor 2448 is prevented. In some embodiments, secure processor 2404 utilizes a shutdown signal to transition motor 2448 to an off state in sleep mode. A third input is provided to the FET switch 2413 by a current sensor 2412 coupled to the battery 2408. The current sensor 2412 monitors the current drawn by the circuit 2400 and, when it detects a current greater than a predetermined threshold, opens the FET switch 2413 to turn off the power to the motor 2448. The FET switch 2413 and motor controller 2443 are coupled to a set of FET switches 2445 configured to control operation of the motor 2448.

The motor current sensor 2446 is coupled in series with the motor 2448 to provide a motor current sensor reading to a current monitor 2447. The current monitor 2447 is coupled to the main processor 2406. The current monitor 2447 provides a signal indicative of the current draw of the motor 2448. The main processor 2406 may utilize a signal from the motor current monitor 2447 to control operation of the motor, e.g., to ensure that the current draw of the motor 2448 is within an acceptable range, to compare the current draw of the motor 2448 to one or more other parameters of the circuit 2400 (such as the position encoder 2440), and/or to determine one or more parameters of the treatment site. In some embodiments, the current monitor 2447 can be coupled to the safety processor 2404.

In some embodiments, actuation of one or more handle controls, such as a firing trigger, causes the main processor 2406 to reduce power to one or more components when the handle controls are actuated. For example, in one embodiment, the firing trigger controls the firing stroke of the cutting member. The cutting member is driven by a motor 2448. Actuation of the firing trigger causes forward operation of the motor 2448 and advancement of the cutting member. During firing, the main processor 2406 closes the FET switch 2451 to remove power from the position encoder 2440. Deactivation of one or more circuit components allows higher power to be delivered to motor 2448. When the firing trigger is released, full power is restored to the deactivated feature, for example, by closing the FET switch 2451 and reactivating the position encoder 2440.

In some embodiments, secure processor 2404 controls the operation of segmented circuit 2400. For example, secure processor 2404 may initiate sequential power-up of segmented circuit 2400, transitions of segmented circuit 2400 into and out of sleep mode, and/or may override one or more control signals from main processor 2406. For example, in the illustrated embodiment, the safety processor 2404 is coupled to a buck converter 2416. The secure processor 2404 controls the operation of the segmented circuit 2400 by activating or deactivating the buck converter 2416 to provide power to the rest of the segmented circuit 2400.

Fig. 26 illustrates one embodiment of a power system 2500 that includes a plurality of daisy-chained power converters 2514, 2516, 2518 configured to be sequentially energized. The plurality of daisy-chained power converters 2514, 2516, 2518 may be sequentially activated by, for example, a security processor during initial power up and/or transition from sleep mode. The safety processor may be powered by a separate power converter (not shown). For example, in one embodiment, when the battery voltage V_BATTWhen coupled to the power system 2500 and/or the accelerometer detects motion in the sleep mode, the safety processor initiates sequential activation of the daisy-chained power converters 2514, 2516, 2518. The security processor activates the 13V boost section 2518. The boost section 2518 is powered on and performs a self test. In some embodiments, the boost section 2518 includes an integrated circuit 2520 configured to boost the source voltage and perform self-testing. The diode D prevents the 5V supply section 2516 from powering up until the boost section 2518 has completed self-checking and provided a signal to the diode D indicating that the boost section 2518 did not identify any errors. In some embodiments, the signal is provided by a secure processor. However, these embodiments are not limited to the particular voltage ranges described in the context of this specification.

The 5V supply section 2516 is sequentially energized after the boost section 2518. The 5V power section 2516 performs a self test during power up to identify any errors in the 5V power section 2516. The 5V power supply section 2516 includes an integrated circuit 2515 configured to be able to provide a reduced voltage from a boosted voltage and to be able to perform error checking. When no error is detected, the 5V power section 2516 completes the sequential power up and provides an activation signal to the 3.3V power section 2514. In some embodiments, the security processor provides an activation signal to the 3.3V power supply stage 2514. The 3.3V power section includes an integrated circuit 2513 configured to be able to provide a reduced voltage from the 5V power section 2516 and to perform error self-checking during power-up. When no errors are detected during the self-test, the 3.3V power supply segment 2514 provides power to the main processor. The primary processor is configured to sequentially energize each of the remaining circuit segments. By sequentially powering the power system 2500 and/or the remainder of the segmented circuit, the power system 2500 reduces the risk of errors, achieves voltage level stability before applying a load, and prevents all hardware from being turned on simultaneously in an uncontrolled manner resulting in large current consumption. However, these embodiments are not limited to the particular voltage ranges described in the context of this specification.

In one embodiment, the power system 2500 includes an over-voltage identification and mitigation circuit. The overvoltage identification and mitigation circuit is configured to detect a monopolar return current in the surgical instrument and interrupt power from the power section when the monopolar return current is detected. The overvoltage identification and mitigation circuit is configured to identify a ground float of the power system. The overvoltage identification and mitigation circuit includes a metal oxide varistor. The overvoltage identification and reduction circuit includes at least one transient voltage suppression diode.

Fig. 27 illustrates one embodiment of a segmented circuit 2600 that includes a single point control segment 2602. Single point control segment 2602 isolates the control hardware of segmented circuit 2600 from the power segments (not shown) of segmented circuit 2600. The control segment 2602 includes, for example, a main processor 2606, a safety processor (not shown), and/or additional control hardware, such as FET switches 2617. The power segment includes, for example, a motor driver, and/or a plurality of motor MOSFETs. The single point control segment 2602 includes a charging circuit 2603 and a rechargeable battery 2608 coupled to a 5V power converter 2616. The charging circuit 2603 and rechargeable battery 2608 isolate the main processor 2606 from the power segment. In some embodiments, a rechargeable battery 2608 is coupled to the safety processor and any additional support hardware. Isolating control segment 2602 from the power segment allows control segment 2602 (e.g., main processor 2606) to remain active (even when the main power supply is removed), provide a filter through rechargeable battery 2608 to keep noise away from control segment 2602, isolate control segment 2602 from drastic changes in battery voltage to ensure proper operation (even during large motor loads), and/or allow real-time operating system (RTOS) to be used by segmented circuit 2600. In some embodiments, the rechargeable battery 2608 provides a reduced voltage, e.g., a voltage of 3.3V, to the main processor. However, these embodiments are not limited to the particular voltage ranges described in the context of this specification.

Use of multiple sensors in which one sensor affects the output or interpretation of a second sensor

Fig. 28 illustrates one embodiment of an end effector 3000 including a first sensor 3008a and a second sensor 3008 b. The end effector 3000 is similar to the end effector 300 described above. End effector 3000 includes a first jaw member or anvil 3002 that is pivotally coupled to a second jaw member 3004. Second jaw member 3004 is configured to receive staple cartridge 3006 therein. The staple cartridge 3006 comprises a plurality of staples (not shown). A plurality of staples can be deployed from the staple cartridge 3006 during a surgical procedure. The end effector 3000 includes a first sensor 3008 a. The first sensor 3008a is configured to measure one or more parameters of the end effector 3000. For example, in one embodiment, the first sensor 3008a is configured to measure a gap 3010 between the anvil 3002 and the second jaw member 3004. The first sensor 3008a can comprise, for example, a hall effect sensor configured to detect a magnetic field generated by the magnet 3012 embedded in the second jaw member 3004 and/or the staple cartridge 3006. As another example, in one embodiment, the first sensor 3008a is configured to measure one or more forces applied to the anvil 3002 by the second jaw member 3004 and/or tissue clamped between the anvil 3002 and the second jaw member 3004.

The end effector 3000 includes a second sensor 3008 b. The second sensor 3008b is configured to measure one or more parameters of the end effector 3000. For example, in various embodiments, the second sensor 3008b may comprise a strain gauge configured to measure an amount of strain in the anvil 3002 during the clamped state. The strain gauge provides an electrical signal whose magnitude varies with the magnitude of the strain. In various embodiments, the first sensor 3008a and/or the second sensor 3008b can include, for example, a magnetic sensor (such as a hall effect sensor), a strain gauge, a pressure sensor, a force sensor, an inductive sensor (such as an eddy current sensor), a resistive sensor, a capacitive sensor, an optical sensor, and/or any other suitable sensor for measuring one or more parameters of the end effector 3000. The first sensor 3008a and the second sensor 3008b may be arranged in a series configuration and/or a parallel configuration. In a series configuration, the second sensor 3008b may be configured to directly affect the output of the first sensor 3008 a. In a parallel configuration, the second sensor 3008b may be configured to indirectly affect the output of the first sensor 3008 a.

In one embodiment, the one or more parameters measured by the first sensor 3008a are correlated to the one or more parameters measured by the second sensor 3008 b. For example, in one embodiment, the first sensor 3008a is configured to measure a gap 3010 between the anvil 3002 and the second jaw member 3004. The gap 3010 represents the thickness and/or compressibility of the tissue section clamped between the anvil 3002 and the staple cartridge 3006. The first sensor 3008a can comprise, for example, a hall effect sensor configured to detect a magnetic field generated by the magnet 3012 coupled to the second jaw member 3004 and/or staple cartridge 3006. Accurate measurements at a single location may describe a compressed tissue thickness corrected for full bite of tissue, but may provide inaccurate results when a partial bite of tissue is disposed between the anvil 3002 and the second jaw member 3004. The partial occlusion of tissue (proximal partial occlusion or distal partial occlusion) changes the clamping geometry of the anvil 3002.

In some embodiments, the second sensor 3008b is configured to detect one or more parameters indicative of a tissue bite type (e.g., full bite, partial proximal bite, and/or partial distal bite). The measurements of the second sensor 3008b can be used to adjust the measurements of the first sensor 3008a to accurately represent the true compressed tissue thickness of the proximally or distally located partial occlusion. For example, in one embodiment, the second sensor 3008b comprises a strain gauge, such as a micro-strain gauge, configured to monitor the magnitude of strain in the anvil during the clamped state. The strain amplitude of the anvil 3002 is used to modify the output of the first sensor 3008a, e.g., a hall effect sensor, to accurately represent the true compressed tissue thickness of the proximally or distally located partial bite. The first sensor 3008a and the second sensor 3008b may be measured in real time during the clamping operation. The real-time measurements allow time-based information to be analyzed, for example, by the primary processor 2006 and used to select one or more algorithms and/or look-up tables from which to identify tissue characteristics and clamp locations to dynamically adjust the tissue thickness measurements.

In some embodiments, the tissue measurements of the first sensor 3008a can be provided to an output device of the surgical instrument 10 coupled to the end effector 3000. For example, in one embodiment, the end effector 3000 is coupled to a surgical instrument 10 that includes a display 2028. The measurement of the first sensor 3008a is provided to a processor, e.g., the primary processor 2006. The primary processor 2006 adjusts the measurement of the first sensor 3008a based on the measurement of the second sensor 3008b to reflect the true tissue thickness of the tissue segment clamped between the anvil 3002 and the staple cartridge 3006. The primary processor 2006 outputs the adjusted tissue thickness measurement and an indication of full or partial occlusion to the display 2028. The operator can determine whether to deploy staples in the staple cartridge 3006 based on the displayed values.

In some embodiments, the first sensor 3008a and the second sensor 3008b can be positioned in different environments, e.g., the first sensor 3008a is pinned at a treatment site within a patient and the second sensor 3008b is positioned external to the patient. The second sensor 3008b may be configured to correct and/or modify the output of the first sensor 3008 a. The first sensor 3008a and/or the second sensor 3008b may comprise, for example, an environmental sensor. The environmental sensor may include, for example, a temperature sensor, a humidity sensor, a pressure sensor, and/or any other suitable environmental sensor.

FIG. 29 is a logic diagram illustrating one embodiment of a method 3020 for determining a measurement of the first sensor 3008a based on input from the second sensor 3008 b. The first signal 3022a is captured by the first sensor 3008 a. First signal 3022a may be conditioned based on one or more predetermined parameters (e.g., a smoothing function, a look-up table, and/or any other suitable conditioning parameters). The second signal 3022b is captured by the second sensor 3008 b. The second signal 3022b may be conditioned based on one or more predetermined conditioning parameters. The first signal 3022a and the second signal 3022b are provided to a processor, e.g., the primary processor 2006. The processor 2006 adjusts the measurement of the first sensor 3022a, represented by the first signal 3022a, based on the second signal 3022b from the second sensor. For example, in one embodiment, the first sensor 3022a comprises a hall effect sensor and the second sensor 3022b comprises a strain gauge. The measurement of the first sensor 3022a is adjusted by the magnitude of the strain measured by the second sensor 3022b to determine the completeness of tissue engagement in the end effector 3000. The adjusted measurement results are displayed 3026 to the operator, for example, via a display 2026 embedded in the surgical instrument 10.

FIG. 30 is a logic diagram illustrating one embodiment of a method 3030 for determining a look-up table for the first sensor 3008a based on input from the second sensor 3008 b. The first sensor 3008a captures a signal 3022a indicative of one or more parameters of the end effector 3000. First signal 3022a may be conditioned based on one or more predetermined parameters (e.g., a smoothing function, a look-up table, and/or any other suitable conditioning parameters). The second signal 3022b is captured by the second sensor 3008 b. The second signal 3022b may be conditioned based on one or more predetermined conditioning parameters. The first signal 3022a and the second signal 3022b are provided to a processor, e.g., the primary processor 2006. The processor 2006 selects a lookup table from one or more available lookup tables 3034a, 3034b based on the value of the second signal. The selected look-up table is used to convert the first signal into a thickness measurement of tissue positioned between the anvil 3002 and the staple cartridge 3006. The adjusted measurement results are displayed 3026 to the operator, for example, via a display 2026 embedded in the surgical instrument 10.

FIG. 31 is a logic diagram illustrating one embodiment of a method 3040 for calibrating a first sensor 3008a in response to inputs from a second sensor 3008 b. The first sensor 3008a is configured to capture a signal 3022a indicative of one or more parameters of the end effector 3000. First signal 3022a may be conditioned based on one or more predetermined parameters (e.g., a smoothing function, a look-up table, and/or any other suitable conditioning parameters). The second signal 3022b is captured by the second sensor 3008 b. The second signal 3022b may be conditioned based on one or more predetermined conditioning parameters. The first signal 3022a and the second signal 3022b are provided to a processor, e.g., the primary processor 2006. The primary processor 2006 corrects 3042 the first signal 3022a in response to the second signal 3022 b. The first signal 3022a is corrected 3042 to reflect the completeness of the tissue bite in the end effector 3000. The corrected signal is displayed 3026 to the operator via, for example, a display 2026 embedded in the surgical instrument 10.

Fig. 32A is a logic diagram illustrating one embodiment of a method 3050 for determining and displaying a thickness of a tissue segment clamped between an anvil 3002 and a staple cartridge 3006 of an end effector 3000. The method 3050 includes obtaining a hall-effect voltage 3052 via, for example, a hall-effect sensor positioned at a distal tip of the anvil 3002. The hall effect voltage 3052 is provided to an analog-to-digital converter 3054 and converted to a digital signal. The digital signal is provided to a processor, e.g., the primary processor 2006. The primary processor 2006 corrects 3056 the curve input for the hall effect voltage 3052 signal. The strain gauge 3058 (e.g., a micro-strain gauge) is configured to measure one or more parameters of the end effector 3000, such as, for example, the magnitude of the strain applied to the anvil 3002 during a clamping operation. The measured strain is converted 3060 into a digital signal and provided to a processor, e.g., the primary processor 2006. The primary processor 2006 utilizes one or more algorithms and/or look-up tables to adjust the hall effect voltages 3052 in response to the strain measured by the strain gauge 3058 to reflect the true thickness and bite integrity of the tissue clamped by the anvil 3002 and staple cartridge 3006. The adjusted thickness is displayed 3026 to the operator via, for example, a display 2026 embedded in the surgical instrument 10.

In some embodiments, the surgical instrument can further include a load element or load sensor 3082. The load cell 3082 may be located, for example, in the shaft assembly 200 (as described above) or in the housing 12 (also as described above). Fig. 32B is a logic diagram illustrating one embodiment of a method 3070 for determining and displaying the thickness of a tissue section clamped between the anvil 3002 and the staple cartridge 3006 of the end effector 3000. The method includes obtaining a hall effect voltage 3072 via, for example, a hall effect sensor positioned at a distal tip of the anvil 3002. The Hall effect voltage 3072 is provided to an analog-to-digital converter 3074 and converted to a digital signal. The digital signal is provided to a processor, e.g., the primary processor 2006. The primary processor 2006 applies a correction 3076 to the curve input of the Hall effect voltage 3072 signal. The strain gauge 3078 (e.g., a micro-strain gauge) is configured to measure one or more parameters of the end effector 3000, such as the magnitude of the strain applied to the anvil 3002 during a clamping operation. The measured strain is converted 3080 to a digital signal and provided to a processor, e.g., the primary processor 2006. The load sensor 3082 measures the clamping force of the anvil 3002 relative to the staple cartridge 3006. The measured clamping force is converted 3084 to a digital signal and provided to a processor, e.g., the primary processor 2006. The primary processor 2006 utilizes one or more algorithms and/or look-up tables to adjust the hall effect voltage 3072 in response to the strain measured by the strain gauge 3078 and the clamping force measured by the load sensor 3082 to reflect the true thickness and bite integrity of the tissue clamped by the anvil 3002 and staple cartridge 3006. The adjusted thickness is displayed 3026 to the operator via, for example, a display 2026 embedded in the surgical instrument 10.

Fig. 33 is a graph 3090 showing an adjusted hall effect thickness measurement 3094 compared to an unmodified hall effect thickness measurement 3092. As shown in fig. 33, the unmodified hall effect thickness measurement 3092 indicates a thicker tissue measurement because a single compensator cannot compensate for partial distal/proximal occlusions that result in incorrect thickness measurements. Adjusted thickness measurements 3094 are produced by, for example, method 3050 shown in fig. 32A. The hall effect thickness measurement 3092 is corrected based on input from one or more additional sensors (e.g., strain gauges). The adjusted hall effect thickness 3094 reflects the true thickness of the tissue positioned between the anvil 3002 and the staple cartridge 3006.

Fig. 34 illustrates one embodiment of an end effector 3100 comprising a first sensor 3108a and a second sensor 3108 b. The end effector 3100 is similar to the end effector 3000 shown in fig. 28. The end effector 3100 includes a first jaw member or anvil 3102 that is pivotally coupled to a second jaw member 3104. The second jaw member 3104 is configured to receive a staple cartridge 3106 therein. The end effector 3100 includes a first sensor 3108a coupled to the anvil 3102. The first sensor 3108a is configured to measure one or more parameters of the end effector 3100, such as a gap 3110 between the anvil 3102 and the staple cartridge 3106. The gap 3110 may correspond to, for example, the thickness of tissue clamped between the anvil 3102 and the staple cartridge 3106. The first sensor 3108a may comprise any suitable sensor for measuring one or more parameters of the end effector. For example, in various embodiments, the first sensor 3108a may include a magnetic sensor (such as a hall effect sensor), a strain gauge, a pressure sensor, an inductive sensor (such as an eddy current sensor), a resistive sensor, a capacitive sensor, an optical sensor, and/or any other suitable sensor.

In some embodiments, the end effector 3100 includes a second sensor 3108 b. The second sensor 3108b is coupled to the second jaw member 3104 and/or staple cartridge 3106. The second sensor 3108b is configured to detect one or more parameters of the end effector 3100. For example, in some embodiments, the second sensor 3108b is configured to detect one or more instrument conditions, such as the color of the staple cartridge 3106 coupled to the second jaw member 3104, the length of the staple cartridge 3106, the clamping status of the end effector 3100, the number of uses/remaining uses of the end effector 3100 and/or the staple cartridge 3106, and/or any other suitable instrument conditions. The second sensor 3108b may include any suitable sensor for detecting one or more instrument states, for example, a magnetic sensor (such as a hall effect sensor), a strain gauge, a pressure sensor, an inductive sensor (such as an eddy current sensor), a resistive sensor, a capacitive sensor, an optical sensor, and/or any other suitable sensor.

The end effector 3100 may be used with the method shown in fig. 29-33. For example, in one embodiment, the input from the second sensor 3108b may be used to correct the input of the first sensor 3108 a. The second sensor 3108b may be configured to detect one or more parameters of the staple cartridge 3106, for example, the color and/or length of the staple cartridge 3106. The detected parameters (e.g., the color and/or length of the staple cartridge 3106) may correspond to one or more characteristics of the cartridge, such as the height of the cartridge deck, the available/optimal tissue thickness for the staple cartridge, and/or the staple pattern in the staple cartridge 3106. Known parameters of the staple cartridge 3106 may be used to adjust the thickness measurements provided by the first sensor 3108 a. For example, if the staple cartridge 3106 has a higher deck height, the thickness measurement provided by the first sensor 3108a may be decreased to compensate for the increased deck height. The adjusted thickness may be displayed to the operator via, for example, a display 2026 coupled to the surgical instrument 10.

Fig. 35 illustrates one embodiment of an end effector 3150 that includes a first sensor 3158 and a plurality of second sensors 3160a, 3160 b. End effector 3150 includes a first jaw member or anvil 3152 and a second jaw member 3154. Second jaw member 3154 is configured to receive staple cartridge 3156. Anvil 3152 can be pivotally moved relative to second jaw member 3154 to clamp tissue between anvil 3152 and staple cartridge 3156. The anvil includes a first sensor 3158. First sensor 3158 is configured to detect one or more parameters of end effector 3150, such as a gap 3110 between anvil 3152 and staple cartridge 3156. Gap 3110 may correspond to, for example, a thickness of tissue clamped between anvil 3152 and staple cartridge 3156. First sensor 3158 may include any suitable sensor for sensing one or more parameters of the end effector. For example, in various embodiments, the first sensor 3158 may include a magnetic sensor (such as a hall effect sensor), a strain gauge, a pressure sensor, an inductive sensor (such as an eddy current sensor), a resistive sensor, a capacitive sensor, an optical sensor, and/or any other suitable sensor.

In some embodiments, the end effector 3150 includes a plurality of second sensors 3160a, 3160 b. Second sensors 3160a, 3160b are configured to detect one or more parameters of end effector 3150. For example, in some embodiments, the second sensors 3160a, 3160b are configured to measure the magnitude of the strain applied to the anvil 3152 during clamping. In various embodiments, the second sensors 3160a, 3160b may include magnetic sensors (such as hall effect sensors), strain gauges, pressure sensors, inductive sensors (such as eddy current sensors), resistive sensors, capacitive sensors, optical sensors, and/or any other suitable sensors. The second sensors 3160a, 3160b may be configured to measure one or more of the same parameter at different locations of the anvil 3152, different parameters at the same location on the anvil 3152, and/or different parameters at different locations on the anvil 3152.

Fig. 36 is a logic diagram illustrating one embodiment of a method 3170 for adjusting the measurements of a first sensor 3158 in response to a plurality of second sensors 3160a, 3160. In one embodiment, the 3172 hall effect voltage is obtained, for example, by a hall effect sensor. The hall effect voltage is converted 3174 by an analog to digital converter. The converted hall effect voltage signal is corrected 3176. The calibration curve represents the thickness of the tissue section positioned between the anvil 3152 and the staple cartridge 3156. 3178a, 3178b a plurality of second measurements are obtained by a plurality of second sensors (e.g., a plurality of strain gauges). The inputs of the strain gauges are converted 3180a, 3180b into one or more digital signals, e.g. by a plurality of electronic mu-strain converting circuits. The corrected hall effect voltage and the plurality of second measurements are provided to a processor, e.g., the primary processor 2006. The main processor utilizes the second measurement and adjusts 3182 the hall effect voltage, for example by applying an algorithm and/or using one or more look-up tables. The adjusted hall effect voltage is indicative of the completeness of the bite of the tissue clamped by anvil 3152 and staple cartridge 3156. The adjusted thickness is displayed 3026 to the operator via, for example, a display 2026 embedded in the surgical instrument 10.

Fig. 37 illustrates one embodiment of a circuit 3190 configured to convert signals from the first sensor 3158 and the plurality of second sensors 3160a, 3160b into digital signals that can be received by a processor (e.g., the primary processor 2006). The circuit 3190 includes an analog-to-digital converter 3194. In some embodiments, analog-to-digital converter 3194 includes a 4-channel, 18-bit analog-to-digital converter. Those skilled in the art will recognize that analog-to-digital converter 3194 may include any suitable number of channels and/or bits to convert one or more inputs from an analog signal to a digital signal. The circuit 3190 includes one or more level shifting resistors 3196 configured to receive input from a first sensor 3158 (e.g., a hall effect sensor). Level shifting resistor 3196 adjusts the input from the first sensor, thereby shifting the value to a higher or lower voltage, depending on the input. Level shift resistor 3196 provides a level shifted input from first sensor 3158 to the analog to digital converter.

In some embodiments, a plurality of second sensors 3160a, 3160b are coupled to bridges 3192a, 3192b within a plurality of circuits 3190. The plurality of bridges 3192a, 3192b may provide filtering to the inputs from the plurality of second sensors 3160a, 3160 b. After the input signal is filtered, the plurality of bridges 3192a, 3192b provide inputs from the plurality of second sensors 3160a, 3160b to an analog-to-digital converter 3194. In some embodiments, a switch 3198 coupled to one or more level shifting resistors may be coupled to the analog-to-digital converter 3194. Switch 3198 is configured to correct one or more of the input signals, for example, from the input of a hall effect sensor. Switch 3198 may be used to provide one or more level shifted signals to adjust the input of one or more of the sensors, e.g., to correct the input of the hall effect sensor accordingly. In some embodiments, trimming is not necessary, and switch 3198 remains in the open position to disconnect the level shifting resistor. Switch 3198 is coupled to analog-to-digital converter 3194. The analog-to-digital converter 3194 provides an output to one or more processors, e.g., the primary processor 2006. The primary processor 2006 calculates one or more parameters of the end effector 3150 based on inputs from the analog-to-digital converter 3194. For example, in one embodiment, the primary processor 2006 calculates the thickness of tissue positioned between the anvil 3152 and the staple cartridge 3156 based on input from one or more sensors 3158, 3160a, 3160 b.

Fig. 38 illustrates one embodiment of an end effector 3200 including a plurality of sensors 3208a-3208 d. End effector 3200 includes an anvil 3202 pivotably coupled to a second jaw member 3204. Second jaw member 3204 is configured to receive staple cartridge 3206 therein. Anvil 3202 includes a plurality of sensors 3208a-3208d thereon. A plurality of sensors 3208a-3208d are configured to detect one or more parameters of end effector 3200 (such as anvil 3202). The plurality of sensors 3208a-3208d may include one or more of the same sensor and/or different sensors. The plurality of sensors 3208a-3208d may include, for example, magnetic sensors (such as hall effect sensors), strain gauges, pressure sensors, inductive sensors (such as eddy current sensors), resistive sensors, capacitive sensors, optical sensors, and/or any other suitable sensors or combinations thereof. For example, in one embodiment, the plurality of sensors 3208a-3208d may include a plurality of strain gauges.

In one embodiment, the plurality of sensors 3208a-3208d allow for a robust tissue thickness sensing approach. By detecting various parameters along the length of the anvil 3202, the plurality of sensors 3208a-3208d allow a surgical instrument (e.g., surgical instrument 10) to calculate tissue thickness in the jaws regardless of occlusion, e.g., partial occlusion or full occlusion. In some embodiments, the plurality of sensors 3208a-3208d includes a plurality of strain gauges. A plurality of strain gauges are configured to measure strain at various points on the anvil 3202. The magnitude and/or slope of the strain at each of the various points on the anvil 3202 may be used to determine the thickness of the tissue between the anvil 3202 and the staple cartridge 3206. The plurality of strain gauges may be configured to optimize the maximum amplitude and/or slope difference based on clamping dynamics to determine thickness, tissue placement, and/or material properties of the tissue. The time-based detection of the plurality of sensors 3208a-3208d during clamping allows the processor (e.g., primary processor 2006) to utilize algorithms and look-up tables to identify tissue characteristics and clamping locations and dynamically adjust the end effector 3200 and/or the tissue clamped between the anvil 3202 and the staple cartridge 3206.

FIG. 39 is a logic diagram illustrating one embodiment of a method 3220 for determining one or more tissue characteristics based on a plurality of sensors 3208a-3208 d. In one embodiment, a plurality of sensors 3208a-3208d generate 3222a-3222d signals indicative of one or more parameters of the end effector 3200. The plurality of resulting signals are converted 3224a-3224d into digital signals and provided to a processor. For example, in one embodiment that includes multiple Strain gauges, multiple electronic μ Strain conversion circuits convert 3224a-3224d Strain gauge signals into digital signals. The digital signal is provided to a processor, e.g., the primary processor 2006. The primary processor 2006 determines 3226 one or more tissue characteristics based on the plurality of signals. The processor 2006 may determine one or more tissue characteristics by applying an algorithm and/or a look-up table. One or more tissue properties are displayed 3026 to the operator via, for example, a display 2026 embedded in the surgical instrument 10.

Fig. 40 illustrates one embodiment of an end effector 3250 including a plurality of sensors 3260a-3260d coupled to a second jaw member 3254. The end effector 3250 includes an anvil 3252 that is pivotably coupled to a second jaw member 3254. Anvil 3252 can be movable relative to second jaw member 3254 to clamp one or more materials therebetween, e.g., tissue segment 3264. Second jaw member 3254 is configured to receive staple cartridge 3256. The first sensor 3258 is coupled to the anvil 3252. The first sensor is configured to detect one or more parameters of the end effector 3150, such as a gap 3110 between the anvil 3252 and the staple cartridge 3256. The gap 3110 may correspond to, for example, a thickness of tissue clamped between the anvil 3252 and the staple cartridge 3256. The first sensor 3258 may include any suitable sensor for detecting one or more parameters of the end effector. For example, in various embodiments, the first sensor 3258 may include a magnetic sensor (such as a hall effect sensor), a strain gauge, a pressure sensor, an inductive sensor (such as an eddy current sensor), a resistive sensor, a capacitive sensor, an optical sensor, and/or any other suitable sensor.

A plurality of second sensors 3260a-3260d is coupled to second jaw member 3254. A plurality of second sensors 3260a-3260d can be integrally formed with second jaw member 3254 and/or staple cartridge 3256. For example, in one embodiment, a plurality of second sensors 3260a-3260d are disposed on an outer row of staple cartridges 3256 (see FIG. 41). The plurality of second sensors 3260a-3260d are configured to detect one or more parameters of the end effector 3250 and/or a section of tissue 3264 clamped between the anvil 3252 and the staple cartridge 3256. The plurality of second sensors 3260a-3260d may include any suitable sensor for detecting one or more parameters of the end effector 3250 and/or tissue section 3264, for example, a magnetic sensor (such as a hall effect sensor), a strain gauge, a pressure sensor, an inductive sensor (such as an eddy current sensor), a resistive sensor, a capacitive sensor, an optical sensor, and/or any other suitable sensor or combination thereof. The plurality of second sensors 3260a-3260d may include the same sensor and/or different sensors.

In some embodiments, the plurality of second sensors 3260a-3260d includes dual-purpose sensors and tissue stabilizing elements. The plurality of second sensors 3260a-3260d includes electrodes and/or sensing geometries configured to generate a stable tissue state when the plurality of second sensors 3260a-3260d engages the tissue segment 3264, e.g., during a clamping operation. In some embodiments, one or more of the plurality of second sensors 3260a-3260d can be replaced with a non-sensing tissue stabilizing element. The second sensors 3260a-3260d generate a stable tissue state by controlling tissue flow, staple deformation, and/or other tissue states during clamping, stapling, and/or other treatment processes.

FIG. 41 illustrates one embodiment of a staple cartridge 3270 that includes a plurality of sensors 3272a-3272h integrally formed therein. The staple cartridge 3270 includes a plurality of rows that house a plurality of apertures for storing staples therein. One or more of the holes in the outer row 3278 is replaced with one of the plurality of sensors 3272a-3272 h. Cutaway portion 3274 is shown to illustrate sensor 3272f coupled to sensor wire 3276 b. The sensor wires 3276a, 3276b can include a plurality of wires for coupling the plurality of sensors 3272a-3272h to one or more circuits of a surgical instrument (e.g., surgical instrument 10). In some embodiments, one or more of the plurality of sensors 3272a-3272h includes a dual purpose sensor and tissue stabilization element having electrodes and/or sensing geometry configured to provide tissue stabilization. In some embodiments, multiple sensors 3272a-3272h can be replaced and/or occupied with multiple tissue stabilizing elements. Tissue stabilization may be provided by, for example, tissue flow and/or staple formation during clamping and/or stapling. The plurality of sensors 3272a-3272h provide signals to one or more circuits of the surgical instrument 10 to enhance feedback of suture performance and/or tissue thickness sensing.

Fig. 42 is a logic diagram illustrating one embodiment of a method 3280 for determining one or more parameters of a tissue segment 3264 clamped within an end effector (e.g., end effector 3250 shown in fig. 40). In one embodiment, the first sensor 3258 is configured to detect one or more parameters of the end effector 3250 and/or a tissue section 3264 positioned between the anvil 3252 and the staple cartridge 3256. A first signal is generated by the first sensor 3258 (step 3282). The first signal is indicative of one or more parameters detected by the first sensor 3258. The one or more second sensors 3260 are configured to detect one or more parameters of the end effector 3250 and/or the tissue segment 3264. Like the first sensor 3258, the second sensor 3260 can be configured to detect the same parameter, another parameter, or a different parameter. A second signal 3284 is generated by a second sensor 3260. The second signal 3284 is indicative of one or more parameters detected by the second sensor 3260. The first signal and the second signal are provided to a processor, e.g., the primary processor 2006. The processor 2006 adjusts the first signal generated by the first sensor 3258 based on the input generated by the second sensor 3260 (step 3286). The adjusted signal may indicate, for example, the true thickness and bite integrity of the tissue section 3264. The adjusted signal is displayed 3026 to the operator via, for example, a display 2026 embedded in the surgical instrument 10.

Fig. 43 illustrates one embodiment of an end effector 3300 including a plurality of redundant sensors 3308a, 3308 b. The end effector 3300 includes a first jaw member or anvil 3302 that is pivotably coupled to a second jaw member 3304. Second jaw member 3304 is configured to receive a staple cartridge 3306 therein. The anvil 3302 can be moved relative to the staple cartridge 3306 to grasp material (e.g., tissue segments) between the anvil 3302 and the staple cartridge 3306. A plurality of sensors 3308a, 3308b are coupled to the anvil. The plurality of sensors 3308a, 3308b are configured to detect one or more parameters of the end effector 3300 and/or a section of tissue positioned between the anvil 3302 and staple cartridge 3306. In some embodiments, the plurality of sensors 3308a, 3308b are configured to detect a gap 3310 between the anvil 3302 and the staple cartridge 3306. The gap 3310 may correspond to, for example, the thickness of tissue positioned between the anvil 3302 and staple cartridge 3306. The plurality of sensors 3308a, 3308b may detect the gap 3310 by, for example, detecting a magnetic field generated by a magnet 3312 coupled to the second jaw member 3304.

In some embodiments, the plurality of sensors 3308a, 3308b include redundant sensors. The redundant sensors are configured to detect the same characteristics of the end effector 3300 and/or the tissue section positioned between the anvil 3302 and staple cartridge 3306. The redundant sensors can comprise, for example, hall effect sensors configured to detect a gap 3310 between the anvil 3302 and staple cartridge 3306. The redundant sensors provide signals representative of one or more parameters, thereby allowing a processor (e.g., primary processor 2006) to evaluate multiple inputs and determine the most reliable input. In some embodiments, redundant sensors are used to reduce noise, glitches, and/or drift. Each of the redundant sensors can be measured in real time during clamping, thereby allowing time-based information to be analyzed and algorithms and/or look-up tables utilized to dynamically identify tissue characteristics and clamp location. The input of one or more of the redundant sensors can be adjusted and/or selected to identify the true tissue thickness and the bite of a tissue segment positioned between the anvil 3302 and staple cartridge 3306.

FIG. 44 is a logic diagram illustrating one embodiment of a method 3320 for selecting the most reliable outputs from a plurality of redundant sensors (e.g., the plurality of sensors 3308a, 3308b shown in FIG. 43). In one embodiment, the first signal is generated by the first sensor 3308 a. The first signal is converted 3322a by an analog-to-digital converter. One or more additional signals are generated by one or more redundant sensors 3308 b. The one or more further signals are converted 3322b by an analog-to-digital converter. The converted signal is provided to a processor, e.g., the primary processor 2006. The main processor evaluates 3324 the redundant inputs to determine the most reliable output. The most reliable output may be selected based on one or more parameters, such as an algorithm, a look-up table, an input from another sensor, and/or an instrument state. After selecting the most reliable output, the processor may select an output based on one or more additional sensors to reflect, for example, the true thickness and bite of the tissue section positioned between the anvil 3302 and staple cartridge 3306. The most reliable output of the adjustment is displayed 3026 to the operator via, for example, the display 2026 embedded in the surgical instrument 10.

Fig. 45 illustrates one embodiment of an end effector 3350 that includes a sensor 3358 having a particular sampling rate to limit or eliminate glitches. The end effector 3350 includes a first jaw member or anvil 3352 that is pivotally coupled to a second jaw member 3354. Second jaw member 3354 is configured to receive a staple cartridge 3356 therein. The staple cartridge 3356 comprises a plurality of staples that can be delivered to a tissue section positioned between the anvil 3352 and the staple cartridge 3356. The sensor 3358 is coupled to the anvil 3352. The sensor 3358 is configured to detect one or more parameters of the end effector 3350, such as a gap 3364 between the anvil 3352 and the staple cartridge 3356. The gap 3364 may correspond to a thickness of material (e.g., tissue segments) and/or a bite integrity of material positioned between the anvil 3352 and the staple cartridge 3356. Sensor 3358 may include any suitable sensor for detecting one or more parameters of end effector 3350, such as, for example, a magnetic sensor (such as a hall effect sensor), a strain gauge, a pressure sensor, an inductive sensor (such as an eddy current sensor), a resistive sensor, a capacitive sensor, an optical sensor, and/or any other suitable sensor.

In one embodiment, the sensor 3358 comprises a magnetic sensor configured to detect a magnetic field generated by an electromagnetic source 3360 coupled to the second jaw member 3354 and/or the staple cartridge 3356. Electromagnetic source 3360 generates a magnetic field that is detected by sensor 3358. The strength of the detected magnetic field may correspond to, for example, the thickness and/or the bite integrity of the tissue positioned between the anvil 3352 and the staple cartridge 3356. In some embodiments, the electromagnetic source 3360 generates a signal of a known frequency (e.g., 1 MHz). In other embodiments, the magnetic field generated by the electromagnetic source 3360 can be adjusted based on, for example, the type of staple cartridge 3356 installed in the second jaw member 3354, one or more additional sensors, algorithms, and/or one or more parameters.

In one embodiment, the signal processor 3362 is coupled to an end effector 3350, e.g., an anvil 3352. The signal processor 3362 is configured to process the signal generated by the sensor 3358 to eliminate glitches and enhance the input from the sensor 3358. In some embodiments, the signal processor 3362 may be positioned independent of the end effector 3350, e.g., in the handle 14 of the surgical instrument 10. In some embodiments, the signal processor 3362 is integrally formed with and/or includes an algorithm executed by a general purpose processor (e.g., the primary processor 2006). The signal processor 3362 is configured to process signals from the sensor 3358 at a particular frequency that is substantially equal to the frequency of the signals generated by the electromagnetic source 3360. For example, in one embodiment, the electromagnetic source 3360 generates a signal at a frequency of 1 MHz. The signal is detected by sensor 3358. The sensor 3358 generates a signal indicative of the detected magnetic field provided to the signal processor 3362. The signal is processed by a signal processor 3362 at a frequency of 1MHz to remove glitches. The processed signal is provided to a processor, e.g., the primary processor 2006. The primary processor 2006 correlates the received signals with one or more parameters of the end effector 3350 (e.g., the gap 3364 of the anvil 3352 and the staple cartridge 3356).

Fig. 46 is a logic diagram illustrating one embodiment of a method 3370 for generating a thickness measurement of a tissue section positioned between an anvil and a staple cartridge of an end effector (e.g., end effector 3350 shown in fig. 45). In one embodiment of the method 3370, the 3372 signal is generated by a modulated electromagnetic source 3360. The generated signal may comprise, for example, a 1MHz signal. The magnetic sensor 3358 is configured to detect 3374 the signal generated by the electromagnetic source 3360. The magnetic sensor 3358 generates a signal indicative of the detected magnetic field and provides the signal to the signal processor 3362. The signal processor 3362 processes 3376 the signal to remove noise, artifacts, and/or enhance the signal. The processed signal is provided to an analog-to-digital converter for conversion 3378 to a digital signal. The digital signal may be corrected 3380, for example, by applying a correction curve input algorithm and/or a look-up table. The signal processing 3376, conversion 3378, and correction 3380 may be performed by one or more circuits. The corrected signal is displayed 3026 to the user via, for example, a display 2026 integrally formed with the surgical instrument 10.

While the various embodiments described thus far include having first and second jaws that are pivotably coupled, the described embodiments are not so limited. For example, in one embodiment, the end effector can comprise a circular stapler end effector. FIG. 47 illustrates one embodiment of a circular stapler 3400 configured to implement one or more of the methods described in FIGS. 28-46. The circular stapler 3400 includes a body 3402. The body 3402 may be coupled to a shaft, e.g., the shaft assembly 200 of the surgical instrument 10. Body 3402 is configured to receive a staple cartridge and/or one or more staples (not shown) therein. The anvil 3404 is movably coupled to the body 3402. The anvil 3404 may be coupled to the body 3402, for example, by a shaft 3406. The shaft 3406 can be received within a cavity (not shown) within the body. In some embodiments, a separation washer 3408 is coupled to the anvil 3404. The separator gasket 3408 may include a buttress or reinforcement material during stitching.

In some embodiments, the circular stapler 3400 includes a plurality of sensors 3410a, 3410 b. The plurality of sensors 3410a, 3410b are configured to detect one or more parameters of the circular stapler 3400 and/or a tissue section positioned between the body 3402 and the anvil 3404. The plurality of sensors 3410a, 3410b can be coupled to any suitable portion of the anvil 3404, for example, positioned below a separation washer 3408. The plurality of sensors 3410a, 3410b can be arranged in any suitable arrangement, e.g., equally spaced around the circumference of the anvil 3404. The plurality of sensors 3410a, 3410b can include any suitable sensor for detecting one or more parameters of the end effector 3400 and/or a tissue section positioned between the body 3402 and the anvil 3404. For example, the plurality of sensors 3410a, 3410b can include magnetic sensors (such as hall effect sensors), strain gauges, pressure sensors, inductive sensors (such as eddy current sensors), resistive sensors, capacitive sensors, optical sensors, any combination thereof, and/or any other suitable sensor.

In one embodiment, the plurality of sensors 3410a, 3410b comprises a plurality of pressure sensors positioned below the separation gasket 3408. Each of the sensors 3410a, 3410b is configured to detect pressure generated by compressed tissue present between the body 3402 and the anvil 3404. In some embodiments, the plurality of sensors 3410a, 3410b are configured to detect the impedance of the tissue section positioned between the anvil 3404 and the body 3402. The detected impedance can be indicative of the thickness and/or integrity of tissue positioned between the anvil 3404 and the body 3402. The plurality of sensors 3410a, 3410b generate a plurality of signals indicative of the sensed pressure. The plurality of generated signals are provided to a processor, such as the primary processor 2006. The primary processor 2006 applies one or more algorithms and/or look-up tables to determine one or more parameters of the end effector 3400 and/or a tissue section positioned between the body 3402 and the anvil 3404 based on inputs from the plurality of sensors 3410a, 3410 b. For example, in one embodiment that includes multiple pressure sensors, the processor 2006 is configured to apply an algorithm to compare the outputs of the multiple sensors 3410a, 3410b with respect to each other and with respect to a predetermined threshold. In one embodiment, if the Δ or difference between the outputs of the plurality of sensors 3410a, 3410b is greater than a predetermined threshold, feedback is provided to the operator, thereby indicating a possibly uneven loading condition. In some embodiments, the end effector 3400 may be coupled to a shaft that includes one or more additional sensors, such as a drive shaft 3504 described below in connection with fig. 50.

FIGS. 48A-48D illustrate the clamping process of the circular stapler 3400 illustrated in FIG. 47. Fig. 48A shows the circular stapler 3400 in an initial position with the anvil 3404 and the body 3402 in a closed configuration. The circular stapler 3400 is positioned at the treatment site in a closed configuration. Once the circular stapler 3400 is positioned, the anvil 3404 is moved distally to disengage the body 3402 and create a gap configured to receive the tissue section 3412 therein, as shown in fig. 48B. The tissue section 3412 is compressed between the anvil 3404 and the body 3402 to a predetermined amount of compression 3414 as shown in fig. 48C. The tissue section 3412 is further compressed between the anvil 3404 and the body 3402. Additional compression deploys one or more staples from the body 3402 into the tissue section 3412. The staples are formed by an anvil 3404. FIG. 48D shows the circular stapler 3400 in a position corresponding to staple deployment. Proper staple deployment depends on obtaining a proper tissue bite between the body 3402 and the anvil 3404. The plurality of sensors 3410a, 3410b disposed on the anvil 3404 allow the processor to provide a proper tissue bite between the anvil 3404 and the body 3402 prior to staple deployment.

Fig. 49 illustrates one embodiment of a circular stapler anvil 3452 and electrical connectors 3466 configured to engage therewith. Anvil 3452 includes an anvil head 3454 coupled to anvil shaft 3456. A breakaway washer 3458 is coupled to anvil head 3452. A plurality of pressure sensors 3460a, 3460b are coupled to anvil head 3452 between anvil head 3452 and release washer 3458. A flex circuit 3462 is formed on the shaft 3456. The flex circuit 3462 is coupled to a plurality of pressure sensors 3460a, 3460 b. One or more contacts 3464 are formed on the shaft 3456 to couple the flex circuit 3462 to one or more circuits, such as the control circuit 2000 of the surgical instrument 10. The flex circuit 3462 may be coupled to one or more circuits by an electrical connector 3466. Electrical connectors 3466 are coupled to anvil 3454. For example, in one embodiment, the shaft 3456 is hollow and configured to receive the electrical connector 3466 therein. Electrical connector 3466 includes a plurality of contacts 3468 configured to engage contacts 3464 formed on anvil shaft 3456. A plurality of contacts 3468 on electrical connector 3466 are coupled to flex circuit 3470 such that the flex circuit is coupled to one or more circuits, for example, control circuit 2000.

Fig. 50 illustrates one embodiment of the surgical instrument 3500 including a sensor 3506 coupled to a drive shaft 3504 of the surgical instrument 3500. The surgical instrument 3500 may be similar to the surgical instrument 10 described above. The surgical instrument 3500 includes a handle 3502 and a drive shaft 3504 coupled to a distal end of the handle. The drive shaft 3504 is configured to receive an end effector (not shown) at the distal end. The sensor 3506 is fixedly mounted in the drive shaft 3504. The sensor 3506 is configured to detect one or more parameters of the drive shaft 3504. The sensors 3506 can include any suitable sensor, for example, magnetic sensors (such as hall effect sensors), strain gauges, pressure sensors, inductive sensors (such as eddy current sensors), resistive sensors, capacitive sensors, optical sensors, and/or any other suitable sensor.

In some embodiments, sensor 3506 comprises a magnetic hall effect sensor. The magnets 3508 are positioned within the drive shaft 3504. Sensor 3506 is configured to detect the magnetic field generated by magnet 3508. The magnets 3508 are coupled to a spring-loaded bracket 3510. A spring-loaded bracket 3510 is coupled to the end effector. The spring-loaded bracket 3510 can be configured to move in response to actuation of the end effector (e.g., compression of the anvil toward the body and/or second jaw member). Spring-loaded bracket 3510 moves magnet 3508 in response to movement of the end effector. Sensor 3506 detects changes in the magnetic field produced by magnet 3508 and produces a signal indicative of the movement of magnet 3508. The movement of the magnet 3508 can correspond to, for example, the thickness of tissue clamped by the end effector. The thickness of the tissue may be displayed to the operator via, for example, the display 3512 embedded in the handle 3502 of the surgical instrument 3500. In some embodiments, hall effect sensor 3508 can be combined with one or more additional sensors (e.g., the pressure sensor shown in fig. 47).

Fig. 51 is a flow diagram illustrating one embodiment of a method 3550 for determining uneven tissue loading in an end effector (e.g., the end effector 3400 shown in fig. 47 coupled to the surgical instrument 3500 shown in fig. 50). In one embodiment, the method 3550 includes utilizing one or more first sensors 3552 (e.g., a plurality of pressure sensors) to detect 3554 the presence of tissue within the end effector. During a clamping operation of the end effector 3400, input P from the pressure sensor is analyzed to determine a value for P. If P is less than 3556 the predetermined threshold, the end effector 3400 continues 3558 clamp operations. If P is greater than or equal to 3560, a predetermined threshold is determined, then clamping is stopped. Δ (difference) between multiple sensors 3552 are compared 3562. If Δ is greater than the predetermined Δ, the surgical instrument 3500 displays 3564 an alert to the user. The alert may include, for example, information indicating that there is uneven clamping in the end effector. If Δ is less than or equal to a predetermined Δ, the input of one or more sensors 3552 is compared to the input from the additional sensors 3566.

In some embodiments, the second sensor 3566 is configured to detect one or more parameters of the surgical instrument 3500. For example, in some embodiments, a magnetic sensor (e.g., a hall effect sensor) is positioned in the shaft 3504 of the surgical instrument 3500. The second sensor 3566 generates a signal indicative of one or more parameters of the surgical instrument 3500. A preset correction curve is applied 3568 to the input from the second sensor 3566. The preset correction curve can adjust 3568 the signal generated by the second sensor 3566 (e.g., the hall voltage generated by a hall effect sensor). For example, in one embodiment, the hall effect voltage is adjusted such that when the gap X1 between the anvil 3404 and the body 3402 is equal to zero, the resulting hall effect voltage is set to a predetermined value. The adjusted sensor 3566 input is used to calculate 3570 the distance X3 between the anvil 3404 and the body 3402 when the pressure threshold P is reached. The clamping process continues 3572 to deploy a plurality of staples into the tissue section clamped in the end effector 3400. The input from the second sensor 3566 is dynamically varied during the clamping process and used to calculate the distance X2 between the anvil 3404 and the body 3402 in real time. The real-time compression percentage is calculated 3574 and displayed to the operator. In one embodiment, the percent compression is calculated as follows: [ ((X3-X2)/X3) × 100 ].

In some embodiments, one or more of the sensors shown in fig. 28-50 are used to indicate: whether the anvil is attached to the body of the surgical device; compressing the tissue space; and/or whether the anvil is in the correct position for removal of the device, or any combination of these indications.

In some embodiments, one or more of the sensors shown in fig. 28-50 are used to affect device performance. One or more control parameters of the surgical device 10 may be adjusted via at least one sensor output. For example, in some embodiments, the speed control of the firing operation may be adjusted by the output of one or more sensors (e.g., hall effect sensors). In some embodiments, one or more of the sensors may adjust the closing and/or clamping operation based on the load and/or tissue type. In some embodiments, the multi-stage compression sensor allows the surgical instrument 10 to stop closing under a predetermined load and/or a predetermined displacement. The control circuit 2000 may apply one or more predetermined algorithms to apply varying compression to the tissue segments, thereby determining the tissue type based on the tissue response, for example. The algorithm may be varied based on the rate of closure and/or predetermined tissue parameters. In some embodiments, one or more sensors are configured to detect tissue characteristics and one or more sensors are configured to detect device characteristics and/or configuration parameters. For example, in one embodiment, the capacitive block may be integrally formed with the staple cartridge to measure the slope.

Circuit and sensor for powering medical devices

Fig. 52 illustrates an embodiment of an end effector 3600 configured to determine one or more parameters of a tissue segment during a clamping operation. The end effector 3600 includes a first jaw member or anvil 3602 that is pivotably coupled to a second jaw member 3604. The second jaw member 3604 is configured to receive a staple cartridge 3606 therein. The staple cartridge 3606 contains a plurality of staples (not shown) configured to be deployed into a tissue section during a clamping and stapling operation. The staple cartridge 3606 includes a staple cartridge deck 3622 having a predetermined height. The staple cartridge 3606 further includes a slot 3624 defined within the body of the staple cartridge that is similar to the slot 193 described above. The hall effect sensor 3608 is configured to detect a distance 3616 between the hall effect sensor 3608 and a magnet 3610 coupled to the second jaw member 3604. A distance 3616 between the hall effect sensor 3608 and the magnet 3610 is indicative of the thickness of tissue positioned between the anvil 3602 and the cartridge deck 3622.

The second jaw member 3604 is configured to receive a variety of staple cartridge 3606 types. The type of staple cartridge 3606 can be varied by, for example, including staples of different lengths, including buttress materials, and/or including different types of staples. In some embodiments, the height 3618 of the staple cartridge deck 3622 can vary based on the type of staple cartridge 3606 coupled to the second jaw member 3604. The changed bin height 3618 can cause the hall effect sensor 3608 to produce inaccurate thickness measurements. For example, in one embodiment, a first bin comprises a first bin deck height X and a second bin comprises a second bin deck height Y, wherein Y > X. The fixed hall effect sensor 3608 and the fixed magnet will produce accurate thickness measurements for only one of the two bin platform heights. In some embodiments, adjustable magnets are used to compensate for various platform heights.

In some embodiments, the second jaw member 3604 and the staple cartridge 3606 include a magnet cavity 3614. The magnet cavity 3614 is configured to receive a magnet 3610 therein. The magnets are coupled to the spring arms 3612. Spring arm 3612 is configured to bias the magnet toward the upper surface of magnet cavity 3614. The depth 3620 of the magnet cavity 3614 varies depending on the deck height 3618 of the staple cartridge 3606. For example, each staple cartridge 3606 may define a cavity depth 3620 such that an upper surface of the cavity 3614 is a set distance from a plane of the deck 3622. The magnet 3610 is biased against the upper surface of the cavity 3614. The magnetic reference of magnet 3610 as viewed by hall effect sensor 3608 is consistent with respect to all bin platforms but is variable with respect to slot 3624. For example, in some embodiments, the upwardly biased magnet 3610 and cavity 3614 provide a set distance 3616 between the hall effect sensor 3608 and the magnet 3610 regardless of the staple cartridge 3606 inserted into the second jaw member 3604. Setting the distance 3616 allows the hall effect sensor 3608 to produce accurate thickness measurements regardless of the type of staple cartridge 3606. In some embodiments, the depth 3620 of the cavity 3614 can be adjusted to correct the hall effect sensor 3608 for one or more surgical procedures.

Fig. 53A and 53B illustrate one embodiment of an end effector 3650 configured to normalize hall effect voltages regardless of the deck height of the staple cartridge 3656. Fig. 53A illustrates an embodiment of an end effector 3650 that includes a first cartridge 3656a inserted therein. End effector 3650 includes a first jaw member or anvil 3652 pivotably coupled to a second jaw member 3654 to grasp tissue therebetween. Second jaw member 3654 is configured to receive staple cartridge 3656 a. Staple cartridge 3656a can comprise a variety of staple lengths, buttress materials, and/or deck heights. A magnetic sensor 3658 (e.g., a hall effect sensor) is coupled to the anvil 3652. The magnetic sensor 3658 is configured to detect the magnetic field detected by the magnet 3660. The detected magnetic field strength is indicative of a distance 3664 between the magnetic sensor 3658 and the magnet 3660, which may be indicative of a thickness of a tissue section grasped between the anvil 3652 and the staple cartridge 3656, for example. As described above, various staple cartridges 3656a can include varying deck heights that produce a corrected compression gap 3664 difference.

In some embodiments, a magnetic attenuator 3662 is coupled to the staple cartridge 3656 a. The magnetic attenuator 3662 is configured to attenuate the magnetic flux generated by the magnet 3660. The magnetic attenuator 3662 is calibrated based on the height of the staple cartridge 3656a to generate magnetic flux. By attenuating the magnet 3660 based on the staple cartridge 3656 type, the magnetic attenuator 3662 normalizes the magnetic sensor 3658 signal to the same level of correction for various deck heights. Magnetic attenuator 3662 may comprise any suitable magnetic attenuator, such as a ferrous metal cap. Magnetic attenuator 3662 is molded into staple cartridge 3656a such that when staple cartridge 3656 is inserted into second jaw member 3654, magnetic attenuator 3662 is positioned over magnet 3660.

In some embodiments, no attenuation of magnets 3660 is required for the deck height of the staple cartridge. Fig. 53B illustrates one embodiment of an end effector 3650 that includes a second staple cartridge 3656B coupled to a second jaw member 3654. Second staple cartridge 3656b includes a corrected deck height that matches magnet 3660 and hall effect sensor 3658, and therefore does not require attenuation. As shown in FIG. 53B, the second staple cartridge 3656B includes a cavity 3666 in place of the magnetic attenuator 3662 of the first staple cartridge 3656 a. In some embodiments, larger and/or smaller attenuation members are provided depending on the height of the cartridge deck. The design of the shape of the attenuating member 3662 may be optimized to produce a feature in the response signal generated by the hall effect sensor 3658 that allows one or more additional bin characteristics to be distinguished.

Fig. 54 is a logic diagram illustrating one embodiment of a method 3670 for determining when tissue compression within an end effector (e.g., the end effector 3650 illustrated in fig. 53A-53B) has reached steady state. In some embodiments, the clinician initiates 3672 a clamping procedure to clamp tissue within the end effector, e.g., between anvil 3652 and staple cartridge 3656. The end effector engages 3674 tissue during the clamping process. Once the tissue has been engaged 3674, the end effector begins 3676 real-time gap monitoring. Real-time gap monitoring techniques monitor the gap between an anvil 3652 and a staple cartridge 3656 of an end effector 3650, for example. The gap may be monitored by, for example, a sensor 3658 (e.g., a hall effect sensor) coupled to the end effector 3650. The sensor 3658 may be coupled to a processor, for example, the primary processor 2006. The processor determines 3678 when tissue clamping conditions of the end effector 3650 and/or staple cartridge 3656 have been reached. Once the processor determines that the tissue has stabilized, the method indicates 3680 that the tissue has stabilized to a user. The indication may be provided by, for example, a display embedded within the surgical instrument 10.

In some embodiments, the gap measurement is provided by a hall effect sensor. Hall effect sensors may be positioned at the distal tip of anvil 3652, for example. The hall effect sensor is configured to measure the gap between the anvil 3652 at the distal tip and the staple cartridge 3656 deck. The measured gap can be used to calculate a jaw closure gap and/or monitor changes in tissue compression of a tissue segment clamped in the end effector 3650. In one embodiment, the hall effect sensor is coupled to a processor, e.g., the primary processor 2006. The processor is configured to receive real-time measurements from the hall effect sensors and compare the received signals to a set of predetermined criteria. For example, in one embodiment, when the gap reading remains unchanged for a predetermined interval (e.g., 3.0 seconds), the stability of the tissue segment is indicated to the user using a logical equation at equal time intervals (e.g., one second). Tissue stabilization may also be indicated after a predetermined period of time (e.g., 15.0 seconds). As another example, tissue stabilization may be indicated when yn +1 yn +2, where y is equal to the gap measurement of the hall effect sensor and n is a predetermined measurement interval. The surgical instrument 10 may display an indication, such as a graphical representation and/or a numerical representation, to the user when the stabilization has been established.

FIG. 55 is a graph 3690 showing various Hall effect sensor readings 3692a-3692 d. As shown in graph 3690, the thickness or compression of the tissue segment stabilizes after a predetermined period of time. The processor (e.g., the primary processor 2006) may be configured to indicate when the calculated thickness from the sensor (e.g., the hall effect sensor) remains relatively consistent or constant over a predetermined period of time. The processor 2006 may indicate to the user that the tissue has stabilized, for example, through a plurality of displays.

FIG. 56 is a logic diagram illustrating one embodiment of a method 3700 for determining when tissue compression within an end effector (e.g., the end effector 3650 shown in FIGS. 53A-53B) has reached steady state. In some embodiments, the clinician initiates 3702 a clamping procedure to clamp tissue within the end effector, e.g., between anvil 3652 and staple cartridge 3656. The end effector engages 3704 tissue during clamping. Once the tissue has been engaged 3704, the end effector begins 3706 real-time gap monitoring. Real-time gap monitoring techniques monitor 3706 the gap between an anvil 3652 and a staple cartridge 3656 of an end effector 3650, for example. The gap may be monitored by, for example, a sensor 3658 (such as a hall effect sensor) coupled to the 3706 end effector 3650. The sensor 3658 may be coupled to a processor, for example, the primary processor 2006. The processor is configured to execute one or more algorithms to determine when the tissue segment compressed by the end effector 3650 has stabilized.

For example, in the embodiment shown in fig. 56, method 3700 is configured to determine the stability of tissue using slope calculations. The processor calculates 3708 the slope S of the input from the sensor (such as a hall effect sensor). The 3708 slope may be calculated by, for example, equation S ═ ((V _1-V _2))/((T _1-T _ 2)). The processor compares 3710 the calculated slope to a predetermined value (e.g., 0.005 volts/second). If the value of the calculated slope is greater than the predetermined value, the processor resets 3712 the count C to zero. If the calculated slope is less than or equal to the predetermined value, the processor increments the value of 3714 count C. The count C is compared 3716 to a predetermined threshold (e.g., 3). If the value of the count C is greater than or equal to the predetermined threshold, the processor indicates 3718 that the tissue segment has stabilized to the user. If the value of count C is less than the predetermined threshold, the processor continues to monitor sensor 3658. In various embodiments, the slope of the sensor input, the change in slope, and/or any other suitable change in the input signal may be monitored.

In some embodiments, an end effector ( end effector 3600, 3650 shown in fig. 52, 53A, and 53B) can include a cutting member configured to be deployed therein. The cutting member may comprise, for example, an I-beam configured to simultaneously cut a tissue segment positioned between the anvil 3602 and the staple cartridge 3608 and deploy staples from the staple cartridge 3608. In some embodiments, the I-beam may include only a cutting member and/or may only deploy one or more staples. Tissue flow during firing can affect proper formation of the staples. For example, during I-beam deployment, fluid in the tissue may cause the thickness of the tissue to temporarily increase, thereby causing improper deployment of the staples.

Fig. 57 is a logic diagram illustrating one embodiment of a method 3730 for controlling an end effector to improve proper staple formation during deployment. The control method 3730 includes generating 3732 a sensor measurement indicative of a thickness of a tissue segment within the end effector 3650, e.g., a hall effect voltage generated by a hall effect sensor. The sensor measurements are converted 3734 to digital signals by an analog-to-digital converter. The digital signal is corrected 3736. Correction 3736 may be performed by, for example, a processor and/or a dedicated correction current. The digital signal is corrected 3736 based on the one or more correction curve inputs. The corrected digital signal is displayed 3738 to the operator via, for example, a display 2026 embedded in the surgical instrument 10. The corrected signal may be displayed 3738 as a thickness measurement and/or a unitless range of tissue segments grasped between the anvil 3652 and the staple cartridge 3656.

In some embodiments, the generated 3732 hall effect voltage is used to control the I-beam. For example, in the illustrated embodiment, the hall effect voltage is provided to a processor (e.g., primary processor 2006) configured to control deployment of an I-beam within the end effector. The processor receives the hall effect voltage and calculates a rate of change of the voltage over a predetermined period of time. The processor compares 3740 the calculated rate of change to a predetermined value x 1. If the calculated rate of change is greater than the predetermined value x1, the processor slows 3742 the speed of the I-beam. The speed may be reduced by, for example, reducing the variable speed by a predetermined unit. If the calculated rate of change of voltage is less than or equal to the predetermined value x1, the processor maintains the current speed of the 3744I-beam.

In some embodiments, the processor may temporarily reduce the speed of the I-beam to compensate for, for example, thicker tissue, uneven loading, and/or any other tissue characteristic. For example, in one embodiment, the processor is configured to monitor the voltage rate of change of the 3740 hall effect sensor. If the rate of change 3740 monitored by the processor exceeds a first predetermined value x1, the processor slows or stops the deployment of the I-beam until the rate of change is less than a second predetermined value x 2. The processor may return the I-beam to a normal speed when the rate of change is less than a second predetermined value x 2. In some embodiments, the sensor input may be generated by, for example, a pressure sensor, a strain gauge, a hall effect sensor, and/or any other suitable sensor. In some embodiments, the processor may implement one or more pause points during deployment of the I-beam. For example, in some embodiments, the processor may implement three predetermined pause points at which the processor pauses the deployment of the I-beam for a predetermined period of time. The pause point is configured to provide optimal tissue flow control.

FIG. 58 is a logic diagram illustrating one embodiment of a method 3750 for controlling an end effector to allow fluid evacuation and provide improved staple formation. Method 3750 includes generating 3752 a sensor measurement, e.g., a hall effect voltage. The sensor measurements may be indicative of, for example, the thickness of a tissue section grasped between the anvil 3652 and the staple cartridge 3656 of the end effector 3650. The resulting signal is provided to an analog-to-digital converter for conversion 3754 to a digital signal. The converted signal is corrected 3756 based on one or more inputs (e.g., a second sensor input and/or a predetermined correction curve). The corrected signal is indicative of one or more parameters of the end effector 3650, such as the thickness of the tissue segment grasped therein. The corrected thickness measurement may be displayed to the user in a thickness and/or unitless range. The corrected thickness may be displayed by, for example, a display 2026 embedded in the surgical instrument 10 that is coupled to the end effector 3650.

In some embodiments, the corrected thickness measurements are used to control the deployment of an I-beam and/or other firing members within the end effector 3650. The corrected thickness measurement is provided to a processor. The processor compares 3760 the change in the corrected measurement to a predetermined threshold percentage x. If the rate of change of the thickness measurements is greater than x, the processor slows 3762 the speed or deployment rate of the I-beam within the end effector. The processor may slow the 3762I-beam down by, for example, reducing the variable speed by a predetermined unit. If the rate of change of the thickness measurements is less than or equal to x, the processor maintains 3764 the speed of the I-beam within the end effector 3650. Real-time feedback of tissue thickness and/or compression allows the surgical instrument 10 to vary firing speeds to allow fluid evacuation and/or provide improved staple formation.

In some embodiments, the sensor reading (e.g., hall effect voltage) generated 3752 by the sensor can be adjusted by one or more additional sensor inputs. For example, in one embodiment, the generated 3752 hall effect voltage may be adjusted by input from micro-strain gauge sensors on anvil 3652. The micro-strain gauge may be configured to monitor the strain amplitude of anvil 3652. The generated 3752 hall effect voltage can be adjusted by the monitored strain magnitude to indicate, for example, partial proximal or distal tissue bite. The time-based detection of micro-strain and hall effect sensor output during clamping allows one or more algorithms and/or look-up tables to identify tissue characteristics and clamp positioning and dynamically adjust tissue thickness measurements to control firing speed of, for example, an I-beam. In some embodiments, the processor may implement one or more pause points during deployment of the I-beam. For example, in some embodiments, the processor may implement three predetermined pause points at which the processor pauses the deployment of the I-beam for a predetermined period of time. The pause point is configured to provide optimal tissue flow control.

Fig. 59A-59B illustrate one embodiment of an end effector 3800 that includes a pressure sensor. The end effector 3800 includes a first jaw member or anvil 3802 that is pivotably coupled to a second jaw member 3804. The second jaw member 3804 is configured to receive a staple cartridge 3806 therein. The staple cartridge 3806 includes a plurality of staples. The first sensor 3808 is coupled to the anvil 3802 at a distal tip. The first sensor 3808 is configured to detect one or more parameters of the end effector, such as a distance or gap 3814 between the anvil 3802 and the staple cartridge 3806. The first sensor 3808 may include any suitable sensor, such as a magnetic sensor. A magnet 3810 can be coupled to the second jaw member 3804 and/or the staple cartridge 3806 to provide a magnetic signal to the magnetic sensor.

In some embodiments, the end effector 3800 includes a second sensor 3812. The second sensor 3812 is configured to detect one or more parameters of the end effector 3800 and/or a tissue segment positioned therebetween. Second sensor 3812 may include any suitable sensor, such as, for example, one or more pressure sensors. The second sensor 3812 can be coupled to the anvil 3802, the second jaw member 3804, and/or the staple cartridge 3806. The signal from the second sensor 3812 may be used to adjust the measurements of the first sensor 3808 to adjust the readings of the first sensor to thereby accurately represent the true compressed tissue thickness of the proximally and/or distally located partial bite. In some embodiments, the second sensor 3812 may be an alternative to the first sensor 3808.

In some embodiments, the second sensor 3812 may include, for example, a single continuous pressure-sensing membrane and/or a series of pressure-sensing membranes. A second sensor 3812 is coupled to the deck of the staple cartridge 3806 along the central axis, covering the slot 3816 as configured to receive the cutting and/or staple deploying member. The second sensor 3812 provides a signal indicative of the magnitude of the pressure applied by the tissue during the clamping operation. During firing of the cutting and/or deployment member, signals from the second sensor 3812 may be severed, for example, by cutting an electrical connection between the second sensor 3812 and one or more circuits. In some embodiments, the cutoff current of the second sensor 3812 may indicate a spent staple cartridge 3806. In other embodiments, the second sensor 3812 may be positioned such that deployment of the cutting and/or deployment member does not sever the connection with the second sensor 3812.

Fig. 60 illustrates one embodiment of an end effector 3850 that includes a second sensor 3862 positioned between the staple cartridge 3806 and the second jaw member 3804. The end effector 3850 includes a first jaw member or anvil 3852 that is pivotably coupled to a second jaw member 3854. Second jaw member 3854 is configured to receive staple cartridge 3856 therein. A first sensor 3858 is coupled to the anvil 3852 at a distal tip. The first sensor 3858 is configured to detect one or more parameters of the end effector 3850, such as a distance or gap 3864 between the anvil 3852 and the staple cartridge 3856. First sensor 3858 may include any suitable sensor, such as a magnetic sensor. A magnet 3860 can be coupled to the second jaw member 3854 and/or the staple cartridge 3856 to provide a magnetic signal to the magnetic sensor. In some embodiments, the end effector 3850 includes a second sensor 3862 that is similar in all respects to the second sensor 3812 of fig. 59A-59B except for being positioned in the staple cartridge 3856 and the second jaw member 3864.

Fig. 61 is a logic diagram illustrating one embodiment of a method 3870 for determining and displaying a thickness of a tissue segment clamped in an end effector according to fig. 59A-59B or fig. 60. The method includes obtaining a hall effect voltage 3872 via, for example, a hall effect sensor positioned at the distal tip of the anvil 3802. The hall effect voltage 3872 is provided to an analog to digital converter 3874 and is converted to a digital signal. The digital signal is provided to a processor, e.g., the primary processor 2006. The primary processor 2006 corrects 3874 the curve input of the hall effect voltage 3872 signal. The pressure sensor (e.g., second sensor 3812) is configured to measure, for example, one or more parameters of the end effector 3800 (step 3880), such as an amount of pressure applied by the anvil 3802 to tissue clamped in the end effector 3800. In some embodiments, the pressure sensor may comprise a single continuous pressure sensing membrane and/or a series of pressure sensing membranes. The pressure sensor may thus be operable to determine a change in measured pressure at different locations between the proximal and distal ends of the end effector 3800. The measured pressure is provided to a processor, e.g., primary processor 2006. The primary processor 2006 utilizes one or more algorithms and/or look-up tables to adjust 3882 the hall effect voltage 3872 in response to the pressure measured by the pressure sensor 3880 to more accurately reflect the thickness of the tissue clamped between, for example, the anvil 3802 and the staple cartridge 3806. The adjusted thickness is displayed 3878 to the operator via, for example, a display 2026 embedded in the surgical instrument 10.

FIG. 62 illustrates one embodiment of an end effector 3900 that includes a plurality of second sensors 3192a-3192b positioned between the staple cartridge 3906 and the elongate channel 3916. The end effector 3900 includes a first jaw member or anvil 3902 that is pivotably coupled to a second jaw member or elongate channel 3904. The elongate channel 3904 is configured to receive a staple cartridge 3906 therein. The anvil 3902 further includes a first sensor 3908 located in the distal tip. The first sensor 3908 is configured to detect one or more parameters of the end effector 3900, such as a distance or gap between the anvil 3902 and the staple cartridge 3906. The first sensor 3908 can include any suitable sensor, for example, a magnetic sensor. The magnet 3910 may be coupled to the elongate channel 3904 and/or the staple cartridge 3906 to provide a magnetic signal to the first sensor 3908. In some embodiments, the end effector 3900 includes a plurality of second sensors 3912a-3912c located between the staple cartridge 3906 and the elongate channel 3904. The second sensors 3912a-3912c may include any suitable sensors, such as piezoresistive pressure membrane strips. In some embodiments, the second sensors 3912a-3912c may be evenly distributed between the distal and proximal ends of the end effector 3900.

In some embodiments, the measurement of the first sensor 3908 may be adjusted using signals from the second sensors 3912a-3912 c. For example, the readings of the first sensor 3908 may be adjusted using signals from the second sensors 3912a-3912c to accurately represent the gap between the anvil 3908 and the staple cartridge 3906, which may vary between the distal and proximal ends of the end effector 3900 depending on the position and/or density of the tissue 3920 between the anvil 3902 and the staple cartridge 3906. Fig. 11 shows an example of partial occlusion of tissue 3920. As shown for purposes of this example, tissue is positioned only in the proximal region of the end effector 3900, thereby creating a high pressure region 3918 located near the proximal region of the end effector 3900 and a corresponding low pressure region 3916 located near the distal end of the end effector.

Fig. 63A and 63B further illustrate the effect of full versus partial occlusion of tissue 3920. Fig. 63A shows a fully occluded end effector 3900 having tissue 3920 with uniform density of tissue 3920. With a complete bite of tissue 3920 having a uniform density, the measured first gap 3914a at the distal tip at the end effector 3900 may be substantially equal to the measured second gap 3922a in the middle or proximal end of the end effector 3900. For example, the first gap 3914a may measure 2.4mm and the second gap may measure 2.3 mm. Fig. 63B illustrates a partially occluded or alternatively a fully occluded end effector 3900 having tissue 3920 of non-uniform density. In this case, first gap 3914b would be measured to be smaller than second gap 3922b measured at the thickest or densest portion of tissue 3920. For example, the first gap may measure 1.0mm, while the second gap may measure 1.9 mm. In the case shown in fig. 63A and 63B, signals from the second sensors 3912a-3912c (e.g., measured pressures at different points along the length of the end effector 3900) may be used by the instrument to determine the arrangement of the tissue 3920 and/or the material properties of the tissue 3920. The instrument is further operable to identify tissue properties and tissue location using the measured pressure over time and dynamically adjust the tissue thickness measurement.

Fig. 64 illustrates one embodiment of an end effector 3950 that includes a coil 3958 and an oscillator circuit 3962 for measuring the gap between the anvil and the staple cartridge 3956. The end effector 3950 includes a first jaw member or anvil 3952 that is pivotally coupled to a second jaw member or elongate channel 3954. The elongate channel 3954 is configured to receive a staple cartridge 3956 therein. In some embodiments, the staple cartridge 3954 further includes a coil 3958 and an oscillator circuit 3962 at the distal end. The coil 3958 and the oscillator circuit 3962 are operable as an eddy current sensor and/or an inductive sensor. The coil 3958 and the oscillator circuit 3962 may detect eddy currents and/or inductance when a target 3960 (e.g., a distal tip of the anvil 3952) is proximate to the coil 3958. The distance or gap between the anvil 3952 and the staple cartridge 3956 may be detected using eddy currents and/or inductance detected by the coil 3958 and the oscillator circuit 3962.

Fig. 65 shows an alternative view of the end effector 3950. As shown, in some embodiments, external wiring 3964 may provide power to oscillator circuit 3962. External wiring 3964 may be disposed along the outside of the elongate channel 3954.

Fig. 66 shows an example of the operation of the coil 3958 for detecting an eddy current 3972 in the target 3960. The alternating current flowing through coil 3958 at a selected frequency creates a magnetic field 3970 around coil 3958. When the coil 3958 is in position 3976a at a particular distance from the target 3960, the coil 3958 will not induce eddy currents 3972. When the coil 3958 is in a position 3976b near the conductive target 3960, a current 3972 is generated in the target 3960. When the coil 3958 is at a location 3976c near a crack in the target 3960, the crack may interrupt the eddy current cycle; in this case, the magnetic field coupled to the coil 3958 changes and the defect signal 3974 can be read by measuring the coil impedance change.

Fig. 67 shows a graph 3980 of measured quality factor 3984, measured inductance 3986, and measured resistance 3988 of coil radius 3958 as a function of a spacing 3978 of coil 3958 relative to a target 3960. Quality factor 3984 is dependent on spacing 3978, while both inductance 3986 and resistance 3988 are functions of displacement. A higher quality factor 3984 results in a more fully reactive sensor. The specific value of inductance 3986 is only constrained by the following requirements: a manufacturable coil 3958 and an actual circuit design that consumes the appropriate amount of energy at the appropriate frequency. The resistance 3988 is a parasitic effect.

Graph 3980 shows how inductance 3986, resistance 3988, and quality factor 3984 depend on target spacing 3978. As the spacing 3978 increases, the inductance 3986 increases by a factor of four, the resistance 3988 decreases slightly, and thus the quality factor 3984 increases. The variation of all three parameters is highly non-linear and each curve tends to fall off approximately exponentially with increasing spacing 3978. The rapid loss of sensitivity with distance severely limits the range of eddy current sensors to about 1/2 coil diameters.

Fig. 68 illustrates one embodiment of an end effector 4000 including an emitter and sensor 4008 disposed between a staple cartridge 4006 and an elongate channel 4004. The end effector 4000 includes a first jaw member or anvil 4002 that is pivotably coupled to a second jaw member or elongate channel 4004. The elongate channel 3904 is configured to receive a staple cartridge 4006 therein. In some embodiments, the end effector 4000 further comprises an emitter and sensor 4008 positioned between the staple cartridge 4006 and the elongate channel 4004. The emitter and sensor 4008 may be any suitable device, for example, a MEMS ultrasound transducer. In some embodiments, the emitters and sensors may be arranged along the length of the end effector 4000.

Fig. 69 shows an embodiment of the emitter and sensor 4008 in operation. The emitter and sensor 4008 is operable to emit pulses 4014 and to sense reflected signals 4016 of the pulses 4014. The emitter and sensor 4008 is also operable to measure the time of flight 4018 between the issuance of the pulse 4014 and the receipt of the reflected signal 4016. The measured time of flight 4018 can be used to determine the thickness of tissue compressed in the end effector 4000 along the entire length of the end effector 4000. In some embodiments, the emitter and sensor 4008 can be coupled to a processor, such as the primary processor 2006. Processor 2006 is operable to utilize time of flight 4018 to determine additional information about the tissue, such as whether the tissue is diseased, protruding, or damaged. The surgical instrument is also operable to communicate this information to an operator of the instrument.

Fig. 70 shows a surface of an embodiment of an emitter and sensor 4008 comprising a MEMS transducer.

Fig. 71 shows a graph 4020 of an example of a reflected signal 4016 that may be measured by the emitter and sensor 4008 of fig. 69. Fig. 71 shows the amplitude 4022 of the reflected signal 4016 as a function of time 4024. As shown, the amplitude of the transmitted pulses 4026 is greater than the amplitude of the reflected pulses 4028a to 4028 c. The amplitude of the transmitted pulse 4026 may have a known or expected value. The first reflected pulse 4028a may be derived, for example, from tissue encapsulated by the end effector 4000. The second reflected pulse 4028b may be derived, for example, from a lower surface of the anvil 4002. The third reflected pulse 4028c may be derived, for example, from the upper surface of the anvil 4002.

Figure 72 illustrates an embodiment of an end effector 4050 configured to determine the position of a cutting member or knife 4058. The end effector 4050 includes a first jaw member or anvil 4052 that is pivotally coupled to a second jaw member or elongate channel 4054. The elongate channel 4054 is configured to receive a staple cartridge 4056 therein. The staple cartridge 4056 further comprises a slot 4058 (not shown) and a cutting member or knife 4062 positioned therein. Knife 4062 is operably coupled to knife bar 4064. The knife bar 4064 is operable to move the knife 4062 from the proximal end to the distal end of the slot 4058. The end effector 4050 can also include an optical sensor 4060 positioned near the proximal end of the slot 4058. The optical sensor may be coupled to a processor, for example, the primary processor 2006. The optical sensor 4060 is operable to emit an optical signal toward the knife bar 4064. The knife bar 4064 may also include an encoder strip 4066 along its length. Encoding strip 4066 may include notches, indentations, reflectors, or any other configuration that is optically readable. Encoding strip 4066 is arranged such that the optical signal from optical sensor 4060 reflects from encoding strip 4066 or passes through encoding strip 4066. As the knife 4062 and knife bar 4064 move 4068 along the slot 4058, the optical sensor 4060 will detect a reflection of the emitted optical signal coupled to the encoding strip 4066. The optical sensor 4060 is operable to send the detected signal to the processor 2006. The processor 2006 can be configured to determine the position of the knife 4062 using the detected signals. The position of blade 4062 can be sensed more accurately by designing encoder strip 4066 so that the detected light signal has gradual increases and decreases.

FIG. 73 shows an example of a code strip 4066 operating with a red LED 4070 and an infrared LED 4072. For purposes of this example only, encoding strip 4066 includes a cutout. When encoding strip 4066 is moved 4068, the light emitted by red LED 4070 will be interrupted as the slit passes in front of it. The infrared LED 4072 will thus detect movement 4068 of the code strip 4066, and by extension, the knife 4062.

Monitoring device degradation based on component evaluation

Fig. 74 illustrates a partial view of the end effector 300 of the surgical instrument 10. In the example form shown in fig. 74, the end effector 300 includes a staple cartridge 1100 that is similar in many respects to staple cartridge 304 (fig. 20). Portions of the end effector 300 are omitted to allow a clearer understanding of the present disclosure. In certain instances, the end effector 300 can include a first jaw (e.g., the anvil 306 (fig. 20)) and a second jaw (e.g., the channel 198 (fig. 20)). In some cases, as described above, channel 198 may accommodate a staple cartridge, such as staple cartridge 304 or staple cartridge 1100. At least one of the channel 198 and the anvil 306 may be moved relative to the other of the channel 198 and the anvil 306 to capture tissue between the staple cartridge 1100 and the anvil 306. Various actuation assemblies are described herein to facilitate movement of the channel 198 and/or anvil 306, for example, between an open configuration (fig. 1) and a closed configuration (fig. 75).

In some cases, as described above, the E-beam 178 can be advanced distally to deploy staples 191 into the captured tissue and/or advance the cutting edge 182 between positions to engage and cut the captured tissue. As shown in fig. 74, the cutting edge 182 may be advanced distally, for example, along a path defined by the slot 193. In some instances, the cutting edge 182 may be advanced from the proximal portion 1102 of the staple cartridge 1100 to the distal portion 1104 of the staple cartridge 1100 to cut the captured tissue, as shown in fig. 74. In some instances, the cutting edge 182 may be proximally retracted from the distal portion 1104 to the proximal portion 1102, such as by proximally retracting the E-beam 178.

In some instances, the cutting edge 182 may be employed to cut tissue captured by the end effector 300 in multiple procedures. The reader will appreciate that repeated use of the cutting edge 182 may affect the sharpness of the cutting edge 182. The reader will also appreciate that as the sharpness of the cutting edge 182 decreases, the force required to cut the captured tissue with the cutting edge 182 may increase. Referring to fig. 74-76, in certain instances, the surgical instrument 10 may include a module 1106 (fig. 76) for monitoring the sharpness of the cutting edge 182 during, before, and/or after operation of the surgical instrument 10, for example, in a surgical procedure. In some cases, the module 1106 may be employed to test the sharpness of the cutting edge 182 prior to cutting the captured tissue with the cutting edge 182. In some cases, the module 1106 may be employed to test the sharpness of the cutting edge 182 after the cutting edge 182 has been used to cut the captured tissue. In some cases, the module 1106 may be employed to test the sharpness of the cutting edge 182 before and after the cutting edge 182 is used to cut the captured tissue. In some cases, a module 1106 may be employed at the proximal portion 1102 and/or at the distal portion 1104 to test the sharpness of the cutting edge 1106.

Referring to fig. 74-76, module 1106 may include one or more sensors, e.g., optical sensor 1108; the optical sensor 1108 of the module 1106 may be employed to test, for example, the reflectance of the cutting edge 182. In some cases, the ability of the cutting edge 182 to reflect light may be correlated to the sharpness of the cutting edge 182. Stated another way, a decrease in sharpness of the cutting edge 182 may result in a decrease in the ability of the cutting edge 182 to reflect light. Thus, in some instances, the bluntness of the cutting edge 182 may be evaluated, for example, by detecting the intensity of light reflected from the cutting edge 182. In some cases, the optical sensor 1108 may define an optical sensing region. The optical sensor 1108 may, for example, be oriented such that an optical sensing region is disposed in the path of the cutting edge 182. When the cutting edge 182 is, for example, in an optical sensing zone, an optical sensor 1108 may be employed to sense light reflected from the cutting edge 182. A decrease in the intensity of the reflected light below a threshold value may indicate that the sharpness of the cutting edge 182 has decreased below an acceptable level.

Referring again to fig. 74-76, module 1106 may include one or more light sources, such as light source 1110. In some cases, the module 1106 may include a microcontroller 1112 ("controller") operably coupled to the optical sensor 1108, as shown in fig. 76. In some cases, the controller 1112 can include a microprocessor 1114 ("processor") and one or more computer-readable media or storage units 1116 ("memory"). In some cases, memory 1116 may store various program instructions that, when executed, may cause processor 1114 to perform the various functions and/or computations described herein. In some cases, the memory 1116 may be coupled to the processor 1114, for example. The power supply 1118 may be configured to provide power to the controller 1112, the optical sensor 1108, and/or the light source 1110, for example. In some cases, power supply 1118 may include a battery (or "battery pack" or "power pack"), such as a lithium ion battery. In certain instances, the battery pack may be configured to be releasably mounted to the handle 14 for supplying power to the surgical instrument 10. A plurality of series-connected battery cells may be used as the power supply 4428. In some cases, power supply 1118 may be replaceable and/or rechargeable, for example.

The controller 1112 and/or other controllers of the present disclosure can be implemented using integrated and/or discrete hardware elements, software elements, and/or a combination of both hardware and software elements. Examples of integrated hardware elements may include processors, microprocessors, microcontrollers, integrated circuits, ASICs, PLDs, DSPs, FPGAs, logic gates, registers, semiconductor devices, chips, microchips, chipsets, microcontrollers, socs, and/or SIPs. Examples of discrete hardware elements may include circuits and/or circuit elements, such as logic gates, field effect transistors, bipolar transistors, resistors, capacitors, inductors, and/or relays. In some cases, for example, the controller 1112 can include a hybrid circuit that includes discrete and integrated circuit elements or components on one or more substrates.

In some cases, controller 1112 and/or other controllers of the present disclosure can be, for example, LM4F230H5QR, available from Texas Instruments. In some cases, the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F processor core, comprising: 256KB of on-chip memory of Single cycle flash memory or other non-volatile memory (up to 40MHz), prefetch buffers to improve performance beyond 40MHz, 32KB of Single cycle SRAM, load with

Internal ROM in software, EEPROM in 2KB, one or more PWM modules, one or more QEI analog, one or more 12-bit ADC with 12 analog input channels, and other features readily available. Other microcontrollers may be readily substituted for use in conjunction with the present disclosure. Accordingly, the present disclosure should not be limited to this context.

In some cases, the light source 1110 may be used to emit light that may be directed, for example, at the cutting edge 182 in the optical sensing zone. The optical sensor 1108 may be used to measure the intensity of light reflected from the cutting edge 182 in an optical sensing region in response to exposure to light emitted by the light source 1110. In some cases, the processor 1114 may receive one or more values of the measured intensity of the reflected light and may store the one or more values of the measured intensity of the reflected light, for example, on the memory 1116. The stored value may be detected and/or recorded before, after, and/or during a surgical procedure performed by the surgical instrument 10, for example.

In some cases, the processor 1114 may compare the measured intensity of the reflected light to a predefined threshold, which may be stored on the memory 1116, for example. In some cases, the controller 1112 may conclude that the sharpness of the cutting edge 182 has fallen below an acceptable level if the measured light intensity exceeds a predefined threshold, e.g., 1%, 5%, 10%, 25%, 50%, 100%, and/or more than 100%. In some cases, the processor 1114 may be used to detect a trend in a stored value of the measured intensity of light reflected from the cutting edge 182 that is in the optical sensing zone.

In some instances, the surgical instrument 10 may include one or more feedback systems, such as feedback system 1120. In some cases, processor 1114 may employ feedback system 1120 to alert a user if the measured light intensity of light reflected from cutting edge 182 in an optical sensing zone exceeds, for example, a stored threshold. In some cases, feedback system 1120 can include, for example, one or more visual feedback systems, such as a display screen, a backlight, and/or an LED. In some cases, feedback system 1120 may include, for example, one or more audible feedback systems, such as a speaker and/or buzzer. In some cases, feedback system 1120 may include, for example, one or more haptic feedback systems. In some cases, feedback system 1120 may include a combination of visual feedback systems, auditory feedback systems, and/or tactile feedback systems, for example.

In some instances, the surgical instrument 10 can include a firing lockout 1122 that can be used to prevent advancement of the cutting edge 182. Various suitable firing LOCKOUT mechanisms are described in more detail in U.S. patent publication 2014/0001231 entitled "FIRING SYSTEM LOCKOUT ARRANGEMENTS FOR SURGICAL INSTRUMENTS", filed on 28/6/2012, which is incorporated herein by reference in its entirety. In some cases, as shown in fig. 76, the processor 1114 can be operatively coupled to a latching mechanism 1122; if it is determined that the measured intensity of light reflected from the cutting edge 182 exceeds, for example, a stored threshold, the processor 1114 may employ a latching mechanism 1122 to prevent advancement of the cutting edge 182. In other words, if the cutting edge is not sharp enough to cut tissue captured by the end effector 300, the processor 1114 can activate the latching mechanism 1122.

In some cases, the optical sensor 1108 and the light source 1110 can be housed at a distal portion of the shaft assembly 200. In some cases, as described above, the sharpness of the cutting edge 182 may be evaluated by the optical sensor 1108 prior to the cutting edge 182 transitioning into the end effector 300. When, for example, the cutting edge 182 is in the shaft assembly 182 and prior to entering the end effector 300, the firing bar 172 (fig. 20) can advance the cutting edge 182 through an optical sensing zone defined by the optical sensor 1108. In some instances, the sharpness of the cutting edge 182 may be evaluated by the optical sensor 1108 after the cutting edge 182 is retracted proximally from the end effector 300. After, for example, the cutting edge 182 is retracted from the end effector 300 into the shaft assembly 200, the firing bar 172 (FIG. 20) can retract the cutting edge 182 through the optical sensing zone defined by the optical sensor 1108.

In some instances, the optical sensor 1108 and the light source 1110 can be housed, for example, at a proximal portion of the end effector 300, which can be located proximally of the staple cartridge 1100. The sharpness of the cutting edge 182 may be evaluated by the optical sensor 1108, for example, after the cutting edge 182 transitions into the end effector 300 but before engaging the staple cartridge 1100. In some instances, the firing bar 172 (fig. 20) can advance the cutting edge 182 through an optical sensing zone defined by the optical sensor 1108 when, for example, the cutting edge 182 is at the end effector 300 but prior to engaging the staple cartridge 1100.

In various circumstances, the sharpness of the cutting edge 182 may be evaluated by the optical sensor 1108 as the cutting edge 182 is advanced through the slot 193 by the firing bar 172. As shown in fig. 74, the optical sensor 1108 and the light source 1110 can be housed, for example, at the proximal portion 1102 of the staple cartridge 1100; and the sharpness of the cutting edge 182 may be evaluated, for example, by an optical sensor 1108 at the proximal portion 1102. The firing bar 172 (fig. 20) can advance the cutting edge 182 through an optical sensing zone defined by an optical sensor 1108 at the proximal portion 1102, e.g., before the cutting edge 182 engages tissue captured between the staple cartridge 1100 and the anvil 306. In some cases, as shown in fig. 74, the optical sensor 1108 and the light source 1110 can be housed, for example, at the distal portion 1104 of the staple cartridge 1100. The sharpness of the cutting edge 182 may be evaluated by an optical sensor 1108 at the distal portion 1104. In certain instances, the firing bar 172 (fig. 20) can advance the cutting edge 182 through an optical sensing zone defined by the optical sensor 1108 at the distal portion 1104, such as after the cutting edge 182 has passed through tissue captured between the staple cartridge 1100 and the anvil 306.

Referring again to fig. 74, the staple cartridge 1100 may include, for example, a plurality of optical sensors 1108 and a plurality of corresponding light sources 1110. In some instances, a pair of optical sensors 1108 and a light source 1110 can be housed, for example, at the proximal portion 1102 of the staple cartridge 1100; and a pair of optical sensors 1108 and a light source 1110 can be housed, for example, at the distal portion 1104 of the staple cartridge 1100. In such cases, the sharpness of the cutting edge 182 may be assessed a first time at the proximal portion 1102, e.g., before engaging tissue, and a second time at the distal portion 1104, e.g., after passing through captured tissue.

The reader will appreciate that the optical sensor 1108 may evaluate the sharpness of the cutting edge 182 multiple times during a surgical procedure. For example, the sharpness of the cutting edge may be assessed a first time, such as during advancement of the cutting edge 182 through the slot 193 in a firing stroke, and a second time, such as during retraction of the cutting edge 182 through the slot 193 in a return stroke. In other words, light reflected from the cutting edge 182 may be measured once by the same optical sensor 1108 as the cutting edge advances through the optical sensing region and once as the cutting edge 182 retracts back through the optical sensing region, for example.

The reader will appreciate that the processor 1114 may receive multiple readings of the intensity of light reflected from the cutting edge 182 from one or more of the optical sensors 1108. In some cases, the processor 1114 can be configured to, for example, ignore outliers and calculate an average reading from a plurality of readings. In some cases, the average reading may be compared to a threshold value, for example, in memory 1116. In some cases, the processor 1114 can be configured to alert a user and/or activate the latching mechanism 1122 via the feedback system 1120, for example, if it is determined that the calculated average reading exceeds a threshold value stored in the memory 1116.

In some instances, as shown in fig. 75, 77, and 78, a pair of optical sensors 1108 and a light source 1110 can be positioned on opposite sides of the staple cartridge 1100. Put another way, the optical sensor 1108 can be positioned on a first side 1124 of the slot 193, for example, and the light source 1110 can be positioned on a second side 1126 (opposite the first side 1124) of the slot 193, for example. In some cases, the pair of optical sensors 1108 and the light source 1110 can be disposed substantially in a plane transverse to the staple cartridge 1100, as shown in FIG. 75. The pair of optical sensors 1108 and the light source 1110 can be oriented to define an optical sensing region that is positioned, for example, on or at least substantially on a plane that intersects the staple cartridge 1100. Alternatively, the pair of optical sensors 1108 and light source 1110 can be oriented to define an optical sensing region that is positioned, for example, proximal to a plane that intersects the staple cartridge 1100, as shown in fig. 78.

In some cases, a pair of optical sensors 1108 and light source 1110 can be positioned on the same side of the staple cartridge 1100. Put another way, as shown in fig. 79, the pair of optical sensors 1108 and the light source 1110 can be positioned on a first side of the cutting edge 182, e.g., the side surface 1128, as the cutting edge 182 advances through the slot 193. In such cases, the light source 1110 may be oriented to direct light at the side 1128 of the cutting edge 182; and the intensity of light reflected from the side surface 1128 measured by the optical sensor 1108 may be indicative of the sharpness of the side surface 1128.

In some cases, as shown in FIG. 80, the second pair of optical sensors 1108 and the light source 1110 may be positioned on a second side, e.g., side 1130, of the cutting edge 182, for example. The second pair may be used to evaluate the sharpness of the side surface 1130. For example, the light sources 1110 in the second pair may be oriented to direct light at the side 1130 of the cutting edge 182; and the intensity of light reflected from side 1130 measured by optical sensor 1108 of the second pair may represent the sharpness of side 1130. In some cases, the processor may be configured to evaluate the sharpness of the cutting edge 182, for example, based on the measured intensity of light reflected from the side surfaces 1128 and 1130 of the cutting edge 182.

In some instances, as shown in fig. 75, a pair of optical sensors 1108 and a light source 1110 can be housed at the distal portion 1104 of the staple cartridge 1100. As shown in fig. 81, the light source 1108 can be positioned, for example, on, or at least substantially on, an axis LL that extends longitudinally along the path of the cutting edge 182 through the slot 193. Further, the light source 1110 may be positioned distal of the cutting edge 182, for example, and oriented to direct light at the cutting edge 182 as the cutting edge advances toward the light source 1110. Further, the optical sensor 1108 may be positioned on, or at least substantially positioned on, an axis AA intersecting the axis LL, as shown in fig. 81. In some cases, axis AA may be, for example, perpendicular to axis LL. In any case, optical sensor 1108 may be oriented to define an optical sensing region, e.g., at the intersection of axis LL and axis AA.

The reader will appreciate that the location, orientation, and/or number of optical sensors and corresponding light sources described herein in connection with the surgical instrument 10 are exemplary embodiments intended for illustrative purposes. The present disclosure may employ various other arrangements of optical sensors and light sources to assess the sharpness of the cutting edge 182.

The reader will appreciate that during each firing of the surgical instrument 10, the advancement of the cutting edge 182 through the tissue captured by the end effector 300 may cause the cutting edge to collect tissue debris and/or body fluids. Such debris may interfere with the ability of the module 1106 to accurately assess the sharpness of the cutting edge 182. In some instances, the surgical instrument 10 may be equipped with one or more cleaning mechanisms that may be used to clean the cutting edge 182, for example, prior to evaluating the sharpness of the cutting edge 182. In some cases, as shown in fig. 82, the cleaning mechanism 1131 can include, for example, one or more cleaning members 1132. In some cases, the cleaning members 1132 may be disposed on opposite sides of the slot 193, for example, to receive the cutting edge 182 between the two sides as the cutting edge 182 advances through the slot 193 (see fig. 82). In some cases, as shown in fig. 82, cleaning member 1132 may include, for example, a wiper blade. In some cases, as shown in fig. 830, the cleaning member 1132 may comprise a sponge, for example. The reader will appreciate that various other cleaning members may be employed, for example, to clean the cutting edge 182.

Referring to fig. 74, in certain instances, the staple cartridge 1100 can include a first pair of optical sensors 1108 and a light source 1110, for example, which can be housed in a proximal portion 1102 of the staple cartridge 1100. In addition, as shown in fig. 74, the staple cartridge 1100 can include a first pair 1132 of cleaning members that can be received in the proximal portion 1102 on opposite sides of the slot 193. The first pair of cleaning members 1132 may be positioned distal to the first pair of optical sensors 1108 and the light source 1110, for example. As shown in fig. 74, the staple cartridge 1100 can include a second pair of optical sensors 1108 and a light source 1110, for example, that can be housed in the distal portion 1104 of the staple cartridge 1100. As shown in fig. 74, the staple cartridge 1100 can include a second pair 1132 of cleaning members that can be received in the distal portion 1104 on opposite sides of the slot 193. The second pair 1132 may be positioned proximal to the second pair 1108 of optical sensors and the light source 1110.

In addition to the above, as shown in fig. 74, the cutting edge 182 can be advanced distally in a firing stroke to cut tissue captured by the end effector 300. As the cutting edge advances, a first assessment of the sharpness of the cutting edge 182 may be performed, for example, by the first pair of optical sensors 1108 and the light source 1110 prior to the cutting edge 182 engaging the tissue. A second assessment of the sharpness of the cutting edge 182 may be performed, for example, by the second pair of optical sensors 1108 and the light source 1110 after the cutting edge 182 has transected the captured tissue. The cutting edge 182 may be advanced through the second pair 1132 of cleaning members prior to a second assessment of the sharpness of the cutting edge 182 to remove any debris gathered by the cutting edge 182 during transection of the captured tissue.

In addition to the above, as shown in fig. 74, the cutting edge 182 may be retracted proximally during the return stroke. A third evaluation of the sharpness of the cutting edge 182 may be performed during the return stroke by the first pair of optical sensors 1108 and the light source 1110 as the cutting edge is retracted. The cutting edge 182 may be advanced through the first pair of cleaning members 1132, for example, prior to a third assessment of the sharpness of the cutting edge 182, to remove any debris gathered by the cutting edge 182 during transection of the captured tissue.

In some cases, one or more of the light sources 1110 can include one or more fiber optic cables. In some cases, one or more flex circuits 1134 may be used to transfer energy from the power source 1118 to the optical sensor 1108 and/or the light source 1110. In some cases, the flex circuit 1134 may be configured to transmit one or more of the readings of the optical sensor 1108 to the controller 1112, for example.

Referring now to FIG. 84, a staple cartridge 4300 is shown; staple cartridge 4300 is similar in many respects to staple cartridge 304 (FIG. 20). For example, the staple cartridge 4300 may be used with the end effector 300. In certain instances, as shown in fig. 84, the staple cartridge 4300 may include a sharpness testing member 4302 that may be used to test the sharpness of the cutting edge 182. In certain instances, the sharpness test member 4302 may be attached to and/or integral with the cartridge body 194 of the staple cartridge 4300, for example. In certain instances, the sharpness test member 4302 may be disposed, for example, in the proximal portion 1102 of the staple cartridge 4300. In some cases, as shown in fig. 84, the sharpness test member 4302 may be disposed on a cartridge deck 4304 of the staple cartridge 4300, for example.

In certain instances, as shown in fig. 84, the sharpness test member 4302 may, for example, extend across a slot 193 of the staple cartridge 4300 to bridge or at least partially bridge a gap defined by the slot 193. In some cases, the sharpness test member 4302 may interrupt, or at least partially interrupt, the path of the cutting edge 182. As the cutting edge 182 advances, for example, during a firing stroke, the cutting edge 182 may engage, cut, and/or pass through the sharpness test member 4302. In certain instances, the cutting edge 182 may be configured to engage, cut, and/or pass through the sharpness test member 4302 prior to engaging tissue captured by the end effector 300, for example, during a firing stroke. In certain instances, the cutting edge 182 may be configured to engage the sharpness test member 4302, e.g., at a proximal end 4306 of the sharpness test member 4302, and exit and/or disengage the sharpness test member 4302 at a distal end 4308 of the sharpness test member 4302. In certain instances, as the cutting edge 182 advances during the firing stroke, the cutting edge 182 may travel and/or cut a distance (D) between the proximal end 4306 and the distal end 4308, e.g., through the sharpness test member 4302.

Referring primarily to fig. 84 and 85, the surgical instrument 10 may include, for example, a sharpness testing module 4310 for testing the sharpness of the cutting edge 182. In some cases, the module 4310 may evaluate the sharpness of the cutting edge 182 by testing the ability of the cutting edge 182 to advance through the sharpness test member 4302. For example, the module 4310 may be configured to observe a period of time required for the cutting edge 182 to completely traverse and/or completely pass through at least a predetermined portion of the sharpness testing member 4302. If the observed time period exceeds a predefined threshold, the module 4310 may conclude, for example, that the sharpness of the cutting edge 182 has dropped below an acceptable level.

In certain instances, the module 4310 can include a microcontroller 4312 ("controller"), which can include a microprocessor 4314 ("processor") and one or more computer-readable media or storage units 4316 ("memory"). In some cases, memory 4316 may store various program instructions that, when executed, may cause processor 4314 to perform the various functions and/or computations described herein. In certain instances, memory 4316 may be coupled to processor 4314, for example. The power supply 4318 may be configured to supply power to the controller 4312, for example. In some cases, the power supply 4138 may include a battery (or "battery pack" or "power pack"), such as a lithium ion battery. In some instances, the battery pack may be configured to be releasably mountable to the handle 14. A plurality of series-connected battery cells may be used as the power source 4318. In some cases, the power source 4318 may be replaceable and/or rechargeable, for example.

In certain instances, processor 4313 may be operably coupled to, for example, feedback system 1120 and/or latching mechanism 1122.

Referring to fig. 84 and 85, module 4310 may include one or more position sensors. An exemplary position SENSOR and POSITIONING SYSTEM suitable FOR use with the present disclosure is described in U.S. patent application serial No. 13/803,210 entitled "SENSOR arrays FOR apparatus position SYSTEM FOR substrate instrumentation" filed on 3, 14, 2013, the disclosure of which is incorporated herein by reference in its entirety. In some cases, module 4310 may include a first position sensor 4320 and a second position sensor 4322. In some cases, the first position sensor 4320 may be used to detect a first position of the cutting edge 182, e.g., at the proximal end 4306 of the sharpness test member 4302; and a second position sensor 4322 may be used to detect a second position of the cutting edge 182, e.g., at the distal end 4308 of the sharpness cutting member 4302.

In some cases, position sensors 4320 and 4322 may be used to provide first and second position signals, respectively, to microcontroller 4312. It should be understood that the position signal may be an analog signal or a digital value depending on the interface between microcontroller 4312 and position sensors 4320 and 4322. In one embodiment, the interface between the microcontroller 4312 and the position sensors 4320 and 4322 may be a standard Serial Peripheral Interface (SPI), and the position signal may be a digital value representing the first and second positions of the cutting edge 182, as described above.

In addition to the above, the processor 4314 may determine a time period between receiving the first position signal and receiving the second position signal. The determined period of time may correspond to the time required for the cutting edge 182 to advance through the sharpness test member 4302 from a first position, e.g., at the proximal end 4306 of the sharpness test member 4302, to a second position, e.g., at the distal end 4308 of the sharpness test member 4302. In at least one example, the controller 4312 may include a time element that may be activated by the processor 4314 upon receiving the first position signal and may be deactivated upon receiving the second position signal. The time period between deactivation and deactivation of the time element may correspond to, for example, the time required for the cutting edge 182 to advance from the first position to the second position. The time element may include a real-time clock, a processor configured to implement timing functionality, or any other suitable timing circuitry.

In various instances, the controller 4312 may, for example, compare the time period required for the cutting edge 182 to advance from the first position to the second position to a predefined threshold to evaluate whether the sharpness of the cutting edge 182 has dropped below an acceptable level. In some cases, the controller 4312 may conclude that the sharpness of the cutting edge 182 has fallen below an acceptable level if the measured time period exceeds a predefined threshold, e.g., 1%, 5%, 10%, 25%, 50%, 100%, and/or more than 100%.

In various circumstances, referring to FIG. 86, the electric motor 4330 can drive the firing bar 172 (FIG. 20) to advance the cutting edge 182 during a firing stroke and/or retract the cutting edge 182 during a return stroke, for example. Motor driver 4332 may control electric motor 4330; and a microcontroller (e.g., microcontroller 4312) can be in signal communication with motor driver 4332. As the electric motor 4330 advances the cutting edge 182, the microcontroller 4312 may, for example, determine the current consumed by the electric motor 4330. In such cases, the force required to advance the cutting edge 182 may correspond to, for example, the current consumed by the electric motor 4330. Still referring to fig. 86, the microcontroller 4312 of the surgical instrument 10 may determine whether the current drawn by the electric motor 4330 during advancement of the cutting edge 182 has increased, and if so, may calculate an incremental percentage of the current.

In some cases, when the cutting edge 182 is in contact with the sharpness test member 4302, the current consumed by the electric motor 4330 may increase significantly due to the resistance of the sharpness test member 4302 against the cutting edge 182. For example, when the cutting edge 182 engages, passes, and/or cuts through the sharpness test member 4302, the current consumed by the electric motor 4330 may increase significantly. The reader will appreciate that the resistance of the sharpness test member 4302 to the cutting edge 182 depends in part on the sharpness of the cutting edge 182; and when the sharpness of the cutting edge 182 is reduced due to repeated use, the resistance of the sharpness test member 4302 to the cutting edge 182 will increase. Thus, the value of the incremental percentage of current consumed by the electric motor 4330 when the cutting edge is in contact with the sharpness test member 4302 may increase, for example, as the sharpness of the cutting edge 182 decreases due to repeated use.

In some cases, the determined value of the incremental percentage of current consumed by electric motor 4330 may be the maximum detected incremental percentage of current consumed by electric motor 4330. In various instances, the microcontroller 4312 may compare the determined value of the incremental percentage of current consumed by the electric motor 4330 to a predefined threshold of the incremental percentage of current consumed by the electric motor 4330. If the determined value exceeds a predefined threshold, the microcontroller 4312 may conclude, for example, that the sharpness of the cutting edge 182 has dropped below an acceptable level.

In some cases, as shown in fig. 86, processor 4314 may be in communication with, for example, feedback system 1120 and/or latching mechanism 1122. In some cases, if the determined value of the incremental percentage of current consumed by electric motor 4330 exceeds a predefined threshold, processor 4314 may alert the user, for example, with feedback system 1120. In some cases, if the determined value of the incremental percentage of current consumed by the electric motor 4330 exceeds a predefined threshold, the processor 4314 may, for example, employ the lockout mechanism 1122 to prevent advancement of the cutting edge 182.

In various instances, the microcontroller 43312 can utilize an algorithm to determine a change in the current consumed by the electric motor 4330. For example, a current sensor may detect the current consumed by the electric motor 4330 during the firing stroke. The current sensor may continuously detect the current consumed by the electric motor and/or may intermittently detect the current consumed by the electric motor. In each case, the algorithm may compare the most recent current reading to, for example, the current reading that is progressing immediately. Additionally or alternatively, the algorithm may compare the sample reading X over the time period X to a previous current reading. For example, the algorithm may compare the sample reading to, for example, sample readings within a previous time period X (such as time period X immediately progressing). In other cases, the algorithm may calculate an average of the current trend consumed by the motor. The algorithm may calculate the average current consumed during time period X (including, for example, the latest current reading), and may compare the average current consumed with, for example, the average current consumed during the immediately progressing time period X.

Referring to fig. 87, a method for evaluating the sharpness of the cutting edge 182 of the surgical instrument 10 is shown; and various responses are listed if the sharpness of the cutting edge 182 falls below and/or below, for example, a warning threshold and/or a high severity threshold. In various instances, a microcontroller (e.g., microcontroller 4312) can be configured to implement the method illustrated in fig. 87. In certain instances, the surgical instrument 10 may include a load sensor 4334 (fig. 86); as shown in fig. 86, microcontroller 4312 may be in communication with load sensor 4334. In certain instances, the load sensor 4334 may comprise, for example, a force sensor, such as a strain gauge, operably coupled to the firing bar 172. In some instances, the microcontroller 4312 may employ a load sensor 4334 to monitor the force (Fx) applied to the cutting edge 182 as the cutting edge 182 advances during the firing stroke.

In certain instances, as shown in fig. 88, the load sensor 4334 may be configured to monitor, for example, the force (Fx) applied to the cutting edge 182 when the cutting edge 182 engages and/or contacts the sharpness test member 4302. The reader will appreciate that the force (Fx) applied to the cutting edge 182 by the sharpness testing member 4302 when the cutting edge 182 engages and/or contacts the sharpness testing member 4302 depends, at least in part, on the sharpness of the cutting edge 182. In some cases, the reduction in sharpness of the cutting edge 182 may result in an increase in the Force (FX) required by the cutting edge 182 to cut or pass through the sharpness test member 4302. For example, as shown in fig. 88, curves 4336, 4338, and 4340 represent the force (Fx) applied to the cutting edge 182 when the cutting edge 182 travels the predefined distance (D) through three identical, or at least substantially identical, sharpness test members 4302. Curve 4336 corresponds to a first sharpness of the cutting edge 182; curve 4338 corresponds to the second sharpness of the cutting edge 182; and curve 4340 corresponds to the third sharpness of the cutting edge 182. The first sharpness is greater than the second sharpness, and the second sharpness is greater than the third sharpness.

In some cases, the microcontroller 4312 may compare the maximum value of the monitored force (Fx) applied to the cutting edge 182 to one or more predefined thresholds. In some cases, as shown in fig. 88, the predefined thresholds may include an alert threshold (F1) and/or a high severity threshold (F2). In some cases, as shown by curve 4336 of fig. 88, the monitored force (Fx) may be, for example, less than the alert threshold (F1). In such cases, as shown in fig. 87, the sharpness of the cutting edge 182 is at a good level and the microcontroller 4312 may take no action to alert the user to the status of the cutting edge 182 or may notify the user that the sharpness of the cutting edge 182 is within an acceptable range.

In some cases, as shown by curve 4338 of fig. 88, the monitored force (Fx) may be, for example, greater than the alert threshold (F1) but less than the high severity threshold (F2). In such cases, as shown in fig. 87, the sharpness of the cutting edge 182 may be blunted but still within acceptable levels. The microcontroller 4312 may take no action to alert the user to the status of the cutting edge 182. Alternatively, the microcontroller 4312 may notify the user that the sharpness of the cutting edge 182 is within an acceptable range. Alternatively or in addition, the microcontroller 4312 may determine or estimate the number of cutting cycles remaining in the life cycle of the cutting edge 182 and may alert the user accordingly.

In some instances, the memory 4316 may include a database or table that correlates the number of cutting cycles remaining in the life cycle of the cutting edge 182 to a predetermined value of the monitored force (Fx). The processor 4314 may, for example, access the memory 4316 to determine the number of cutting cycles remaining in the life cycle of the cutting edge 182 (which corresponds to a particular measurement of the monitored force (Fx) and may alert the user to the number of cutting cycles remaining in the life cycle of the cutting edge 182.

In some cases, as shown by curve 4340 of fig. 88, the monitored force (Fx) may be, for example, greater than the high severity threshold (F2). In such cases, as shown in fig. 87, the sharpness of the cutting edge 182 may be below an acceptable level. In response, the microcontroller 4312 may, for example, employ a feedback system 1120 to alert the user that the cutting edge 182 is too dull for safe use. In some cases, microcontroller 4312 may employ lockout mechanism 1122 to prevent advancement of cutting edge 182, for example, upon detecting that the monitored force (Fx) exceeds a high severity threshold (F2). In some cases, microcontroller 4312 may employ a feedback system 1122, for example, to provide instructions to a user for resetting latching mechanism 1122.

Referring to fig. 89, a method is illustrated for determining, for example, whether a cutting edge (e.g., cutting edge 182) is sufficiently sharp for transecting tissue having a particular tissue thickness captured by the end effector 300. In some cases, microcontroller 4312 may be used, for example, to perform the method illustrated in FIG. 16. As described above, repeated use of the cutting edge 182 may blunt or reduce the sharpness of the cutting edge 182, thereby increasing the force required by the cutting edge 182 to transect the captured tissue. Put another way, the level of sharpness of the cutting edge 182 may be defined, for example, by the force required by the cutting edge 182 to transect the captured tissue. The reader will appreciate that the force required for the cutting edge 182 to transect the captured tissue may also depend on the thickness of the captured tissue. In some cases, for example, the greater the thickness of the captured tissue, the greater the force required by the cutting edge 182 to transect the captured tissue, at the same level of sharpness.

In some cases, for example, the cutting edge 182 may be sharp enough to transect captured tissue having a first thickness, but may not be sharp enough to transect captured tissue having a second thickness greater than the first thickness. In some cases, for example, if the captured tissue has a tissue thickness that is within a particular tissue thickness range, the level of sharpness of the cutting edge 182 defined by the force required for the cutting edge 182 to transect the captured tissue may be sufficient to transect the captured tissue. In certain instances, as shown in fig. 90, the memory 4316 may store one or more predefined tissue thickness ranges for tissue captured by the end effector 300; and a predefined threshold force associated with a predefined tissue thickness range. In some cases, each predefined threshold force may represent a minimum level of sharpness of a cutting edge 182 adapted to transect captured tissue having a tissue thickness (Tx) covered by a range of tissue thicknesses associated with the predefined threshold force. In some cases, if the force (Fx) required by the cutting edge 182 to transect the captured tissue having the tissue thickness (Tx) exceeds a predefined threshold force, e.g., associated with a predefined tissue thickness range encompassing the tissue thickness (Tx), the cutting edge 182 may not be sharp enough to transect the captured tissue.

In some cases, the predefined threshold force and its corresponding predefined tissue thickness range may be stored in a database and/or table (e.g., table 4342) on memory 4316, as shown in fig. 90. In certain instances, the processor 4314 can be configured to receive a measurement of the force (Fx) required by the cutting edge 182 to transect the captured tissue and a measurement of the tissue thickness (Tx) of the captured tissue. Processor 4314 may access table 4342 to determine a predefined tissue thickness range encompassing the measured tissue thickness (Tx). Further, processor 4314 may compare the measured force (Fx) to a predefined threshold force associated with a predefined tissue thickness range encompassing the tissue thickness (Tx). In some cases, if the measured force (Fx) exceeds, for example, a predefined threshold force, the processor 4314 may conclude that the cutting edge 182 may not be sharp enough to transect the captured tissue.

In addition to the above, processor 4314 may employ one or more tissue thickness sensing modules (e.g., tissue thickness sensing module 4336) to determine the thickness of the captured tissue. Various suitable tissue thickness sensing modules are described in this disclosure. In addition, various TISSUE THICKNESS sensing devices and methods suitable for use with the present disclosure are disclosed in U.S. patent publication US 2011/0155781 entitled "SURGICAL CUTTING INSTRUMENT THAT ANALYZES TISSUE THICKNESS," filed on 24.12.2009, the entire disclosure of which is incorporated herein by reference.

In some cases, the processor 4314 may employ the load cell 4334 to measure the force (Fx) required by the cutting edge 182 to transect the captured tissue including the tissue thickness (Tx). The reader will appreciate that the force applied to the cutting edge 182 by the captured tissue when the cutting edge 182 engages and/or contacts the captured tissue may increase as the cutting edge 182 advances against the captured tissue until reaching a force (Fx) at which the cutting edge 182 may transect the captured tissue. In some cases, the processor 4314 may employ the load cell 4334 to continuously monitor the force exerted by the captured tissue against the cutting edge 182 as the cutting edge 182 is advanced against the captured tissue. Processor 4314 may continuously compare the monitored force to a predefined threshold force associated with a predefined tissue thickness range encompassing a tissue thickness (Tx) of the captured tissue. In some cases, if the monitored force exceeds, for example, a predefined threshold force, the processor 4314 may conclude that the cutting edge is not sharp enough to safely transect the captured tissue.

The method illustrated in fig. 89 lists various example actions that may be taken by the processor 4313, for example, in the event that the cutting edge 182 is determined to be not sharp enough to safely transect the captured tissue. In some cases, microcontroller 4312 may alert the user, e.g., through feedback system 1120, that the cutting edge 182 is too dull for safe use. In some cases, the microcontroller 4312 can employ the lockout mechanism 1122 to prevent advancement of the cutting edge 182, for example, when it is determined that the cutting edge 182 is not sharp enough to safely transect the captured tissue. In some cases, microcontroller 4312 may employ a feedback system 1122, for example, to provide instructions to a user for resetting latching mechanism 1122.

Multi-motor control for powered medical devices

Fig. 91-93 illustrate various embodiments of devices, systems, and methods that employ a common control module for use with multiple motors in conjunction with a surgical instrument (e.g., surgical instrument 4400). The surgical instrument 4400 is similar in many respects to other surgical instruments described in the present disclosure, such as the surgical instrument 10 of fig. 1 described in greater detail above. For example, as shown in fig. 91, the surgical instrument 4400 includes a housing 12, a handle 14, a closure trigger 32, a shaft assembly 200, and a surgical end effector 300. Accordingly, for the sake of brevity and clarity of the present disclosure, a detailed description of certain features of the same surgical instrument 4400 as the surgical instrument 10 will not be repeated herein.

Referring primarily to fig. 92, the surgical instrument 4400 may include a plurality of motors that can be activated to perform various functions in conjunction with the operation of the surgical instrument 4400. In some cases, the first motor may be activated to perform a first function; the second motor may be activated to perform a second function; and the third motor may be activated to perform a third function. In some instances, multiple motors of the surgical instrument 4400 may be individually activated to cause articulation motions, closure motions, and/or firing motions in the end effector 300. Articulation motions, closure motions, and/or firing motions can be transmitted to the end effector 300, for example, via the shaft assembly 200.

In certain instances, as shown in fig. 92, the surgical instrument 4400 can include a firing motor 4402. The firing motor 4402 is operably coupled to a firing drive assembly 4404, which may be configured to transmit firing motions generated by the motor 4402 to the end effector 300. In some instances, the firing motion produced by the motor 4402 can cause, for example, the staples 191 to be deployed from the staple cartridge 304 into the tissue captured by the end effector 300 and/or cause the cutting edge 182 to be advanced to cut the captured tissue.

In some instances, as shown in fig. 92, the surgical instrument 4400 may include an articulation motor 4406, for example. The motor 4406 is operably coupled to an articulation drive assembly 4408, which may be configured to transmit articulation motions generated by the motor 4406 to the end effector 300. In some instances, the articulation motions can result in, for example, articulation of the end effector 300 relative to the shaft assembly 200. In some instances, the surgical instrument 4400 may include a closure motor, for example. The closure motor may be operably coupled to a closure drive assembly, which may be configured to transmit a closure motion to the end effector 300. In some cases, the closing motion can cause, for example, the end effector 300 to transition from the open configuration to the approximated configuration to capture tissue. The reader will appreciate that the motors and their corresponding drive assemblies described herein are intended to be examples of the types of motors and/or drive assemblies that may be used in conjunction with the present disclosure. The surgical instrument 4400 may include various other motors that may be used to perform various other functions in conjunction with the operation of the surgical instrument 4400.

As described above, the surgical instrument 4400 may include a plurality of motors, which may be configured to perform various independent functions. In some instances, multiple motors of the surgical instrument 4400 may be activated individually or independently to perform one or more functions, while other motors remain inactive. For example, the articulation motor 4406 may be activated to cause the end effector 300 to articulate while the firing motor 4402 remains inactive. Alternatively, the firing motor 4402 can be activated to fire a plurality of staples 191 and/or advance the cutting edge 182, while the articulation motor 4406 remains inactive.

In some instances, the surgical instrument 4400 may include a common control module 4410 that can be used with multiple motors of the surgical instrument 4400. In some cases, the common control module 4410 may regulate one of the plurality of motors at a time. For example, the common control module 4410 may be individually coupled to multiple motors of the surgical instrument 4400, respectively. In some instances, the multiple motors of the surgical instrument 4400 may share one or more common control modules, such as the module 4410. In some instances, multiple motors of the surgical instrument 4400 may independently or selectively engage a common control module 4410. In certain instances, the module 4410 can be switched from engaging one of the plurality of motors of the surgical instrument 4400 to engaging another of the plurality of motors of the surgical instrument 4400.

In at least one example, the module 4410 can be selectively switched between operably engaging the articulation motor 4406 and operably engaging the firing motor 4402. In at least one example, as shown in fig. 92, the switch 4414 can be moved or transitioned between a plurality of positions and/or states (e.g., a first position 4416 and a second position 4418). In the first position 4416, the switch 4414 may electrically couple the module 4410 to the articulation motor 4406; and in the second position 4418, the switch 4414 may electrically couple the module 4410 to the firing motor 4402, for example. In some instances, the module 4410 can be electrically coupled to the articulation motor 4406 to control 4406 operation when the switch 4414 is in the first position 4416, thereby articulating the end effector 300 to a desired position. In certain instances, when the switch 4414 is in the second position 4418, the module 4410 can be electrically coupled to the firing motor 4402, for example, to control the operation of the motor 4402 to fire the plurality of staples 191 and/or advance the cutting edge 182. In some cases, switch 4414 may be a mechanical switch, an electromechanical switch, a solid state switch, or any suitable switching mechanism.

Referring now to fig. 93, for clarity of the present disclosure, the outer housing of the handle 14 of the surgical instrument 4400 is removed and several features and elements of the surgical instrument 4400 are also removed. In some instances, as shown in fig. 93, the surgical instrument 4400 may include a joint 4412 that can be selectively transitioned between a plurality of positions and/or states. In a first position and/or state, the joint 4412 may couple the module 4410 to a first motor, e.g., the articulation motor 4406; and in a second position and/or state, the joint 4412 may couple the module 4410 to a second motor, e.g., the firing motor 4402. The present disclosure contemplates additional positions and/or states of the joint 4412.

In some cases, the joint 4412 is movable between a first position and a second position, wherein the module 4410 is coupled to a first motor in the first position and a second motor in the second position. In some cases, when the joint 4412 is moved from the first position, the module 4410 is disengaged from the first motor; and when the joint 4412 is moved from the second position, the module 4410 is separated from the second motor. In some cases, the switch or trigger may be configured to transition the connector 4412 between multiple positions and/or states. In some instances, the triggers can be movable to simultaneously actuate the end effector and transition the control module 4410 from operably engaging one of the motors of the surgical instrument 4400 to operably engaging another one of the motors of the surgical instrument 4400.

In at least one example, as shown in fig. 93, the closure trigger 32 can be operably coupled to the joint 4412 and can be configured to transition the joint 4412 between a plurality of positions and/or states. As shown in fig. 93, the closure trigger 32 can be moved, e.g., during a firing stroke, to transition the joint 4412 from the first position and/or state to the second position and/or state while transitioning the end effector 300 to the approximated configuration to capture tissue through the end effector, for example.

In certain instances, in a first position and/or state, the module 4410 can be electrically coupled to a first motor, e.g., the articulation motor 4406, and in a second position and/or state, the module 4410 can be electrically coupled to a second motor, e.g., the firing motor 4402. In a first position and/or state, the module 4410 can be engaged with the articulation motor 4406 to allow a user to articulate the end effector 300 to a desired position; and the module 4410 may remain engaged with the articulation motor 4406 until the trigger 32 is actuated. When a user actuates the closure trigger 32 to capture tissue with the end effector 300 in a desired position, the joint 4412 can be transitioned or shifted to transition the module 4410 from operably engaging the articulation motor 4406, for example, to operably engaging the firing motor 4402, for example. Once operative engagement with the firing motor 4402 is achieved, the module 4410 can control the firing motor 4402; and the module 4410 can activate the motor 4402 in response to a user input, for example, to fire a plurality of staples 191 and/or to advance the cutting edge 182.

In some cases, as shown in fig. 93, the module 4410 may comprise a plurality of electrical and/or mechanical contacts 4411 adapted to couple with a connector 4412. Each of the plurality of motors of the surgical instrument 4400 that share the module 4410 may comprise one or more corresponding electrical and/or mechanical contacts 4413, for example, adapted to couple with the connector 4412.

In various instances, the motor of the surgical instrument 4400 can be an electric motor. In some instances, one or more of the motors of the surgical instrument 4400 may be a direct current brushed drive motor having a maximum rotational speed of about 25,000RPM, for example. In other constructions, the motor of the surgical instrument 4400 may include one or more motors selected from the group consisting of brushless motors, cordless motors, synchronous motors, stepper motors, or any other suitable electric motor.

In various instances, as shown in fig. 92, the common control module 4410 may include a motor driver 4426, which may include one or more H-bridge Field Effect Transistors (FETs). The motor driver 4426 may regulate power transmitted from the power supply 4428 to the motor coupled to the module 4410, for example, based on input from a microcontroller 4420 ("controller"). In some cases, the controller 4420 may be employed, for example, to determine the current consumed by the motor when the motor is coupled to the module 4410, as described above.

In some cases, the controller 4420 may comprise a microprocessor 4422 ("processor") and one or more computer-readable media or storage units 4424 ("memory"). In some cases, memory 4424 may store various program instructions that, when executed, may cause processor 4422 to perform various functions and/or computations as described herein. In some cases, one or more of the memory units 4424 can be coupled to the processor 4422, for example.

In some cases, power supply 4428 may be used, for example, to supply power to controller 4420. In some cases, power supply 4428 may include a battery (or "battery pack" or "power pack"), such as a lithium ion battery. In certain instances, the battery pack may be configured to be releasably mountable to the handle 14 for supplying power to the surgical instrument 4400. A plurality of series-connected battery cells may be used as the power supply 4428. In some cases, power supply 4428 may be replaceable and/or rechargeable, for example.

In various instances, the processor 4422 may control the motor driver 4426 to control the position, rotational direction, and/or speed of a motor coupled to the module 4410. In certain instances, the processor 4422 may signal the motor driver 4426 to stop and/or deactivate the motor coupled to the module 4410. It is to be understood that the term "processor" as used herein includes any suitable microprocessor, microcontroller, or other basic computing device that combines the functions of a computer's Central Processing Unit (CPU) onto one integrated circuit or at most several integrated circuits. A processor is a multipurpose programmable device that receives digital data as input, processes the input according to instructions stored in its memory, and then provides the result as output. Because the processor has internal memory, it is an example of sequential digital logic. The operands of the processor are numbers and symbols represented in a binary numerical system.

In one case, processor 4422 may be any type of single-core or multi-core processor, such as those known under the trade name ARM Cortex, manufactured by Texas Instruments. In some cases, microcontroller 4420 may be, for example, LM4F230H5QR, available from Texas Instruments. In at least one example, the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F processor core that includes: 256KB of on-chip memory of Single cycle flash memory or other non-volatile memory (up to 40MHz), prefetch buffers to improve performance beyond 40MHz, 32KB of Single cycle SRAM, load with

Internal ROM for software, EEPROM for 2KB, one or more PWM modules, one or more QEI analogs, one or more 12-bit ADCs with 12 analog input channels, and for productsOther features readily available from the data sheet. Other microcontrollers could be readily substituted for use with module 4410. Accordingly, the present disclosure should not be limited to this context.

In certain instances, the memory 4424 may comprise program instructions for controlling each of the motors of the surgical instrument 4400 that may be coupled to the module 4410. For example, the memory 4424 may include program instructions for controlling the articulation motor 4406. When the articulation motor 4406 is coupled to the module 4410, such program instructions may cause the processor 4422 to control the articulation motor 4406 to articulate the end effector 300 in accordance with user inputs. As another example, the memory 4424 may include program instructions for controlling the firing motor 4402. When the firing motor 4402 is coupled to the module 4410, such program instructions can cause the processor 4422 to control the firing motor 4402 to fire the plurality of staples 191 and/or advance the cutting edge 182 in accordance with the user input.

In some cases, one or more mechanisms and/or sensors (e.g., sensor 4430) may be used to prompt processor 4422 to use program instructions that should be used in a particular setting. For example, when the module 4410 is coupled to the articulation motor 4406, the sensor 4430 may prompt the processor 4422 to use program instructions associated with articulation of the end effector 300; and when the module 4410 is coupled to the firing motor 4402, the sensor 4430 can prompt the processor 4422 to use the program instructions associated with firing the surgical instrument 4400. In some cases, the sensor 4430 may comprise a position sensor, for example, which may be used to sense the position of the switch 4414. Thus, when the switch 4414 is detected by the sensor 4430 as being in the first position 4416, for example, the processor 4422 may use the program instructions associated with articulation of the end effector 300; and the processor 4422 may use the program instructions associated with firing the surgical instrument 4400 when the sensor 4430 detects, for example, that the switch 4414 is in the second position 4418.

Referring now to fig. 94, for clarity of the present disclosure, the outer housing of the surgical instrument 4400 is removed and several features and elements of the surgical instrument 4400 are also removed. As shown in fig. 94, the surgical instrument 4400 may include a plurality of sensors that may be used to perform various functions in conjunction with the operation of the surgical instrument 4400. For example, as shown in fig. 94, the surgical instrument 4400 may include a sensor A, B, and/or a C. In some cases, sensor a may be used, for example, to perform a first function; sensor B may be used, for example, to perform a second function; and sensor C may be used, for example, to perform a third function. In certain instances, for example, sensor a may be used to sense the thickness of tissue captured by the end effector 300 during the first segment of the closure stroke; sensor B may be used to sense tissue thickness during a second segment of the closure stroke after the first segment; and sensor C may be used to sense the tissue thickness during a third segment of the closure stroke following the second segment. In some cases, sensors A, B, and C may be disposed, for example, along end effector 300.

In some cases, as shown in fig. 94, sensors A, B, and C may be arranged such that, for example, sensor a is disposed proximal to sensor B and sensor C is disposed proximal to sensor B. In some cases, as shown in fig. 94, for example, sensor a may sense the tissue thickness of the tissue captured by the end effector 300 at the first location; sensor B may sense a tissue thickness of tissue captured by the end effector 300 at a second location distal to the first location; and the sensor C may sense a tissue thickness of tissue captured by the end effector 300 at a third location distal to the second location. The reader will appreciate that the sensors described herein are intended to be examples of the types of sensors that may be used in connection with the present disclosure. The present disclosure may employ other suitable sensors and sensing configurations.

In some instances, the surgical instrument 4400 may include a common control module 4450, which may be similar in many respects to the module 4410. For example, a module 4450 similar to the module 4410 may include a controller 4420, a processor 4422, and/or a memory 4424. In some cases, the power supply 4428 may supply power to the module 4450, for example. In some instances, the surgical instrument 4400 may include a plurality of sensors, such as the sensors A, B, and C, which may be activated to perform various functions in conjunction with the operation of the surgical instrument 4400. In some cases, one of the sensors A, B, and C, for example, may be activated individually or independently to perform one or more functions while the other sensor remains inactive. In some instances, multiple sensors of the surgical instrument 4400 (e.g., the sensors A, B, and C) may share the module 4450. In some cases, only one of the sensors A, B, and C at a time may be coupled to the module 4450. In some instances, multiple sensors of the surgical instrument 4400 can be coupled to the module 4450, for example, individually or independently. In at least one example, module 4450 can be selectively switched between operative engagement with sensor a, sensor B, and/or sensor C.

In certain instances, as shown in fig. 94, the module 4450 may be disposed in the handle 14, for example, and the sensors that share the module 4450 may be disposed in the end effector 300, for example. The reader will appreciate that the module 4450 and/or the sensors sharing the module 4450 are not limited to the locations indicated above. In some cases, the module 4450 and the sensors that share the module 4450 may be provided in the end effector 300, for example. Other arrangements of the locations of the sensors for the module 4450 and the common module 4450 are contemplated by the present disclosure.

In some instances, as shown in fig. 94, the joint 4452 may be used to control the coupling and/or decoupling of sensors of the surgical instrument 4400 to and from the module 4450. In some cases, the joint 4452 may be selectively transitioned between multiple positions and/or states. In a first position and/or state, the joint 4452 may couple the module 4450 to sensor a, for example; in the second position and/or state, the joint 4452 may couple the module 4450 to sensor B, for example; and in a third position and/or state, the joint 4452 may couple the module 4450 to sensor C, for example. The present disclosure contemplates additional positions and/or states of the joint 4452.

In some cases, the joint 4452 can be movable, for example, between a first position, a second position, and/or a third position, where the module 4450 is coupled to a first sensor in the first position, a second sensor in the second position, and a third sensor in the third position. In some cases, the module 4450 is disengaged from the first sensor when the joint 4452 is moved from the first position; when the joint 4452 moves from the second position, the module 4450 is separated from the second sensor; and when the joint 4452 moves from the third position, the module 4450 is separated from the third sensor. In some cases, a switch or trigger may be configured to enable the junction 4452 to transition between multiple positions and/or states. In some instances, the trigger can be movable to, for example, simultaneously actuate the end effector and transition the control module 4450 from one of the sensors operably engaging the common module 4450 to another of the sensors operably engaging the common module 4450.

In at least one example, as shown in fig. 94, the closure trigger 32 can be operably coupled to the joint 4450 and can be configured to transition the joint 4450 between a plurality of positions and/or states. As shown in fig. 94, the closure trigger 32 can be configured to move between a plurality of positions, such as during a firing stroke, to transition the joint 4450 between a first position and/or state, such as where the module 4450 is electrically coupled to sensor a, a second position and/or state, such as where the module 4450 is electrically coupled to sensor B, and/or a third position and/or state, such as where the module 4450 is electrically coupled to sensor C.

In some instances, a user may actuate the closure trigger 32 to capture tissue through the end effector 300. Actuation of the closure trigger may cause the junction 4452 to transition or shift to transition the module 4450 from, for example, operably engaging sensor a to, for example, operably engaging sensor B, and/or from, for example, operably engaging sensor B to, for example, operably engaging sensor C.

In some cases, the module 4450 may be coupled to sensor a when the trigger 32 is in the first actuated position. The module 4450 may be disengaged from sensor a when the trigger 32 is actuated through the first actuation position toward the second actuation position. Alternatively, the module 4450 may be coupled to sensor a when the trigger 32 is in the unactuated position. The module 4450 may be disengaged from sensor a when the trigger 32 is actuated through the unactuated position toward the second actuated position. In some cases, the module 4450 may be coupled to sensor B when the trigger 32 is in the second actuated position. The module 4450 may be disengaged from sensor B when the trigger 32 is actuated through the second actuation position toward the third actuation position. In some cases, the module 4450 may be coupled to sensor C when the trigger 32 is in the third actuated position.

In some cases, as shown in fig. 94, the module 4450 may comprise a plurality of electrical and/or mechanical contacts 4451 adapted to couple with a connector 4452. Each of the plurality of sensors of the surgical instrument 4400 sharing the module 4450 may comprise one or more corresponding electrical and/or mechanical contacts 4453 adapted to interface with the interface 4452, for example.

In some cases, the processor 4422 may receive input from multiple sensors of the common module 4450 when the sensors are coupled to the module 4452. For example, when sensor a is coupled to module 4450, processor 4422 may receive input from sensor a; when sensor B is coupled to module 4450, processor 4422 may receive input from sensor B; and when sensor C is coupled to module 4450, processor 4422 may receive input from sensor C. In some cases, the input may be a measurement, for example, a measurement of tissue thickness of tissue captured by the end effector 300. In some cases, the processor 4422 may store input from one or more of the sensors A, B, and C on the memory 4426. In some cases, processor 4422 may perform various calculations based on input provided by, for example, sensors A, B, and C.

Local display of tissue parameter stability

Fig. 95A and 1B illustrate one embodiment of an end effector 5300 that includes a staple cartridge 5306 that further includes two Light Emitting Diodes (LEDs) 5310. The end effector 5300 is similar to the end effector 300 described above. The end effector includes a first jaw member or anvil 5302 that is pivotally coupled to a second jaw member or elongate channel 5304. The elongate channel 5304 is configured to receive a staple cartridge 5306 therein. The staple cartridge 5306 includes a plurality of staples (not shown). A plurality of staples can be deployed from the staple cartridge 5306 during a surgical procedure. The staple cartridge 5306 further includes two LEDs 5310 mounted on an upper surface or cartridge platform 5308 of the staple cartridge 5306. The LEDs 5310 are mounted such that they will be visible when the anvil 5304 is in the closed position. Furthermore, the LEDs 5310 may be bright enough to be visible through any tissue that may obscure a direct view of the LEDs 5310. Additionally, one LED 5310 can be mounted on either side of the staple cartridge 5306 such that at least one LED 5310 is visible from either side of the end effector 5300. The LED 5310 can be mounted near the proximal end of the staple cartridge 530, as shown, or at the distal end of the staple cartridge 5306.

The LED 5310 may be in communication with a processor or microcontroller, such as microcontroller 1500 of fig. 19. The microcontroller 1500 can be configured to detect a characteristic of the tissue compressed against the cartridge deck 5308 by the anvil 5304. The tissue encapsulated by the end effector 5300 may change height as fluid within the tissue seeps from the layers of tissue. Suturing tissue before the tissue has stabilized sufficiently can affect the effectiveness of the suture. Tissue stability is expressed by the rate of change, where the rate of change indicates how quickly the tissue enclosed by the end effector is changing height.

An LED 5310 mounted to the staple cartridge 5306, located in the field of view of the instrument operator, can be used to indicate the rate at which the enclosed tissue is stabilizing and/or whether the tissue has reached steady state. The LEDs 5310 may, for example, be configured to blink at a rate directly associated with the rate of tissue stabilization, i.e., may initially blink quickly, blink more slowly as the tissue stabilizes, and remain stationary while the tissue stabilizes. Alternatively, the LED 5310 may initially blink slowly, blink more rapidly with the temperature of the tissue, and extinguish when the tissue is stable.

The LED 5310 mounted on the staple cartridge 5306 can additionally or alternatively be used to indicate other information. Examples of other information include, but are not limited to: whether the end effector 5300 is enclosing a sufficient amount of tissue, whether the staple cartridge 5306 is suitable for enclosing tissue, whether more tissue is enclosed than is suitable for the staple cartridge 5306, whether the staple cartridge 5306 is incompatible with the surgical instrument, any other indicator that would be useful to an operator of the instrument. The LED 5310 may indicate information by flashing at a particular rate, illuminating or extinguishing in particular instances, illuminating in different colors for different information. Alternatively or additionally, the LEDs 5310 may be used to illuminate the operating area. In some embodiments, the LEDs 5310 can be selected to emit ultraviolet or infrared light to illuminate information that is not visible under normal light, where the information is printed on the staple cartridge 5300 or on a tissue compensator (not shown). Alternatively or in addition, the staples can be coated with a fluorescing dye and the wavelength of the LED 5310 can be selected such that the LED 5310 causes the fluorescing dye to emit light. Illuminating the staples with the LEDs 5310 allows the operator of the instrument to view the staples after they have been driven.

Returning to fig. 95A and 95B, fig. 95A illustrates a side view of the end effector 5300 with the anvil 5304 in the closed position. By way of example, the illustrated embodiment includes one LED 5310 located on either side of the bin platform 5308. Fig. 95B illustrates a three-quarter view of the end effector 5300 with the anvil 5304 in an open position, and one LED 5310 on either side of the cartridge platform 5308.

Fig. 96A and 96B illustrate one embodiment of an end effector 5300 that includes a staple cartridge 5356 that further includes a plurality of LEDs 5360. The staple cartridge 5356 includes a plurality of LEDs 5360 mounted to a cartridge platform 5358 of the staple cartridge 5356. The LEDs 5360 are mounted such that they will be visible when the anvil 5304 is in the closed position. Furthermore, the LEDs 5360 may be bright enough to be visible through any tissue that may obscure a direct view of the LEDs 5360. Additionally, the same number of LEDs 5360 can be mounted on either side of the staple cartridge 5356 such that the same number of LEDs 5360 are visible from either side of the end effector 5300. The LED 5360 can be mounted near a proximal end of the staple cartridge 5356, as shown, or can be mounted at a distal end of the staple cartridge 5356.

The LED 5360 may be in communication with a processor or microcontroller, such as microcontroller 1500 of fig. 15. The microcontroller 1500 can be configured to detect a characteristic of the tissue compressed against the cartridge deck 5358 by the anvil 5304, e.g., the rate of stabilization of the tissue, as described above. LED 5360 can be used to indicate the rate at which the encapsulated tissue is becoming stable and/or whether the tissue has reached a steady state. The LEDs 5360 can be configured to illuminate, for example, in an order beginning at the proximal end of the staple cartridge 5356, wherein each subsequent LED 5360 illuminates at a rate at which the enclosed tissue is stabilizing; when the tissue is stable, all of the LEDs 5360 may be illuminated. Alternatively, the LEDs 5360 may be illuminated in an order beginning at the distal end of the staple cartridge 5356. However, another alternative form of LED 5360 lights up in a continuous, repeating sequence, where the sequence begins at the proximal or distal end of LED 5360. The rate and/or repetition rate at which the LEDs 5360 are illuminated can indicate the rate at which the encapsulated tissue is stabilizing. It should be understood that these are merely examples of how the LEDs 5360 may indicate information about tissue, and that other combinations of the order in which the LEDs 5360 are lit, the rate at which they are lit, and/or their lit or extinguished states may also be used. It should also be appreciated that the LED 5360 may be used to communicate some other information to the operator of the surgical instrument or to illuminate the work area, as described above.

Returning to fig. 96A and 96B, fig. 96A illustrates a side view of the end effector 5300 with the anvil 5304 in the closed position. By way of example, the illustrated embodiment includes a plurality of LEDs 5360 located on either side of the bin platform 5358. Fig. 96B illustrates a three-quarter view of the end effector 5300 with the anvil 5304 in the open position, showing the plurality of LEDs 5360 located on either side of the cartridge deck 5358.

Fig. 97A and 97B illustrate one embodiment of an end effector 5300 including a staple cartridge 5406 that further includes a plurality of LEDs 5410. Staple cartridge 5406 includes a plurality of LEDs 5410 mounted on a cartridge platform 5408 of staple cartridge 5406, wherein LEDs 5410 are arranged continuously from a proximal end to a distal end of staple cartridge 5406. The LEDs 5410 are mounted such that they will be visible when the anvil 5302 is in the closed position. The same number of LEDs 5410 can be mounted on either side of staple cartridge 5406 such that the same number of LEDs 5410 are visible from either side of end effector 5300.

The LED 5410 may be in communication with a processor or microcontroller, such as the microcontroller 1500 of fig. 15. The microcontroller 1500 can be configured to detect a characteristic of the tissue compressed against the cartridge platform 5408 by the anvil 5304, e.g., the rate of stabilization of the tissue, as described above. The LEDs 5410 can be configured to light up or off in a desired sequence or grouping to indicate a rate of stabilization of the tissue and/or that the tissue has stabilized. The LED 5410 may also be configured to communicate some other information to the operator of the surgical instrument or to illuminate the work area, as described above. Additionally or alternatively, the LEDs 5410 can be configured to indicate which regions of the end effector 5300 include stable tissue, and/or which regions of the end effector 5300 are encapsulating tissue, and/or whether those regions are encapsulating sufficient tissue. LED 5410 may also be configured to indicate whether any portion of the encapsulated tissue is not suitable for staple cartridge 5406.

Returning to fig. 97A and 97B, fig. 97A shows a side view of the end effector 5300 with the anvil 5304 in a closed position. By way of example, the illustrated embodiment includes a plurality of LEDs 5410 located on either side of the cartridge platform 5408 from the proximal end to the distal end of the staple cartridge 5406. Fig. 97B illustrates a three-quarter view of the end effector 5300 with the anvil 5304 in an open position, showing a plurality of LEDs 5410 from the proximal end to the distal end of the staple cartridge 5406 and located on either side of the cartridge platform 5408.

Accessory with integrated sensor for quantifying tissue compression

Fig. 98A illustrates an embodiment of an end effector 5500 that includes a tissue compensator 5510 that also includes a layer of conductive elements 5512. The end effector 5500 is similar to the end effector 300 described above. The end effector 5500 comprises a first jaw member or anvil 5502 that is pivotally coupled to a second jaw member 5504 (not shown). The second jaw member 5504 is configured to receive a staple cartridge 5506 therein (not shown). The staple cartridge 5506 includes a plurality of staples (not shown). A plurality of staples 191 can be deployed from the staple cartridge 3006 during a surgical procedure. In some embodiments, the end effector 5500 further comprises a tissue compensator 5510 removably positioned on the anvil 5502 or staple cartridge 5506. Figure 98B illustrates a detail view of a portion of the tissue compensator 5510 illustrated in figure 98A.

As described above, the plurality of staples 191 can be deployed between an unfired position and a fired position such that the staple legs 5530 move through and penetrate tissue 5518 compressed between the anvil 5502 and the staple cartridge 5506 and contact the staple forming surface of the anvil 5502. In embodiments that include the tissue compensator 5510, the staple legs 5530 also penetrate and pierce the tissue compensator 5510. As the staple legs 5530 deform against the staple forming surface of the anvil, each staple 191 can capture a portion of the tissue 5518 and the tissue compensator 5510 and apply a compressive force to the tissue 5518. The tissue compensator 5510 is thus retained in place with the staples 191 after the surgical instrument 10 is withdrawn from the patient. Because they will be held by the patient's body, the tissue compensator 5510 is constructed of a bio-durable and/or biodegradable material. The TISSUE COMPENSATOR 5510 is described in more detail in U.S. patent 8,657,176 entitled "TISSUE COMPENSATOR FOR TISSUE COMPENSATOR" which is incorporated herein by reference in its entirety.

Returning to fig. 98A, in some embodiments, the tissue compensator 5510 comprises a layer of conductive elements 5512. The conductive elements 5512 can include any combination of conductive materials having any variety of configurations, such as coils, wire or wire meshes, conductive strips, conductive plates, circuits, microprocessors, or any combination thereof. A layer including a conductive element 5512 may be positioned on the anvil facing surface 5514 of the tissue compensator 5510. Alternatively or in addition, a layer of conductive elements 5512 can be positioned on the staple cartridge facing surface 5516 of the tissue compensator 5510. Alternatively or in addition, the layer of conductive elements 5512 can be embedded within the tissue compensator 5510. Alternatively, the layer of conductive elements 5512 may comprise all of the tissue compensator 5510, for example, when the conductive material is uniformly or non-uniformly distributed in the material comprising the tissue compensator 5510.

Fig. 98A shows an embodiment of an anvil portion 5502 in which a tissue compensator 5510 is removably attached to an end effector 5500. The tissue compensator 5510 will be attached in this manner prior to insertion of the end effector 5500 into the patient. Additionally or alternatively, the tissue compensator 5610 can be attached to the staple cartridge 5506 (not shown) after or before the staple cartridge 5506 is applied to the end effector 6600 and before the device is inserted into a patient.

FIG. 99 illustrates various example embodiments for detecting the distance between the anvil 5502 and the upper surface of the staple cartridge 5506 using a layer of conductive elements 5512 and conductive elements 5524, 5526 and 5528 in the staple cartridge 5506. The distance between the anvil 5502 and the staple cartridge 5506 indicates the amount and/or density of tissue 5518 compressed therebetween. Additionally or alternatively, this distance can indicate which regions of the end effector 5500 contain tissue. The tissue 5518 thickness, density, and/or position may be communicated to an operator of the surgical instrument 10.

In the illustrated example embodiment, the layer of conductive elements 5512 is positioned on the anvil facing surface 5514 of the tissue compensator 5510 and includes one or more coils 5522 in communication with the microprocessor 5520. The microprocessor 5500 may be located in the end effector 5500 or any component thereof, or may be located in the housing 12 of the instrument, or may include any of the microprocessors or microcontrollers described previously herein. In the illustrated example embodiment, the staple cartridge 5506 further comprises a conductive element, which may be any one of the following elements: one or more coils 5524, one or more conductive plates 5526, wire mesh 5528, or any other convenient configuration, or any combination thereof. The electrically conductive elements of the staple cartridge 5506 may communicate with the same microprocessor 5520 or some other microprocessor in the instrument.

When the anvil 5502 is in the closed position and thus compressing the tissue 5518 against the staple cartridge 5506, the layer of conductive elements 5512 of the tissue compensator 5510 can capacitively couple with conductors in the staple cartridge 5506. The strength of the capacitive field between the layer of conductive elements 5512 and the conductive elements of the staple cartridge 5506 may be used to determine the amount of tissue 5518 being compressed. Alternatively, the staple cartridge 5506 may comprise an eddy current sensor in communication with the microprocessor 5520, wherein the eddy current sensor is operable to sense the distance between the anvil 5502 and the upper surface of the staple cartridge 5506 using eddy currents.

It should be understood that other configurations of the conductive element are possible, and that the embodiment of fig. 99 is merely exemplary and not limiting. For example, in some embodiments, a layer of conductive elements 5512 can be positioned on the staple cartridge facing surface 5516 of the tissue compensator 5510. Additionally, in some embodiments, the conductive elements 5524, 5526, and/or 5528 can be positioned on or within the anvil 5502. Thus, in some embodiments, the layer of conductive elements 5512 can capacitively couple with conductive elements in the anvil 5502 and thereby sense a characteristic of the tissue 5518 encapsulated within the end effector.

It can also be appreciated that the tissue compensator 5512 can comprise a layer of conductive elements 5512 on both the anvil facing surface 5514 and the cartridge facing surface 5516. The system for detecting the amount, density, and/or position of the tissue 5518 compressed against the staple cartridge 5506 by the anvil 5502 may include conductors or sensors located in the anvil 5502, the staple cartridge 5506, or both. Embodiments including conductors or sensors located in both the anvil 5502 and the staple cartridge 5506 may optionally achieve improved results by allowing differential analysis of the information available from this configuration.

Fig. 100A and 100B illustrate an embodiment of a tissue compensator 5510 including a layer of conductive elements 5512 in operation. Fig. 100A shows one of the plurality of staples 191 after it has been deployed. As shown, the staples 191 have penetrated both the tissue 5518 and the tissue compensator 5510. The conductive element 5512 layer may comprise, for example, a mesh. Upon penetrating the layer of conductive elements 5512, the staple legs 5530 can pierce the wire mesh, thereby altering the conductivity of the layer of conductive elements 5512. This change in conductivity can be used to indicate the location of each of the plurality of pins 191. The positions of the staples 191 can be compared relative to the expected positions of the staples, and such comparison can be used to determine whether any of the staples are unfired or whether any of the staples are not in the position they are expected to be in.

Fig. 100A also shows the staple legs 5530 not being fully deformed. Fig. 100B shows the staple leg 5530 properly and fully deformed. As shown in fig. 100B, when the staple legs 5530 are deformed against the staple forming surface of the anvil 5502 and fold back into the tissue 5518, the layer of conductive elements 5512 can be pierced a second time by the staple legs 5530. A second discontinuity in the layer of conductive element 5512 can be used to indicate complete formation of the nail 191 (as shown in fig. 100B) or incomplete formation of the nail 191 (as shown in fig. 100A).

Fig. 101A and 101B illustrate an embodiment of an end effector 5600 that includes a tissue compensator 5610 that also includes a conductor 5620 embedded therein. The end effector 5600 includes a first jaw member or anvil 5602 that is pivotally coupled to a second jaw member 5604. Second jaw member 5604 is configured to receive staple cartridge 5606 therein. In some embodiments, the end effector 5600 further includes a tissue compensator 5610 removably positioned on the anvil 5602 or staple cartridge 5606.

Turning first to fig. 4B, fig. 4B illustrates a cross-sectional view of a tissue compensator 5610 removably positioned on a staple cartridge 5606. The cross-sectional view shows a series of conductors 5620 embedded within the material comprising the tissue compensator 5610. A series of conductors 5620 may be arranged in an opposing configuration, and opposing elements may be separated by an insulating material. A series of conductors 5620 are each coupled to one or more conductive wires 5622. Conductive line 5622 allows a series of conductors 5620 to communicate with a microprocessor, such as microprocessor 1500. A series of conductors 5620 may span the width of the tissue compensator 5610 such that they will be in the path of the cutting member or knife bar 280. As the knife bar 280 advances, it will sever, break, or otherwise damage the conductor 5620 and thereby indicate its position within the end effector 5600. The series of conductors 5610 may include conductive elements, electronic circuits, microprocessors, or any combination thereof.

Turning now to fig. 101A, fig. 101A illustrates a close-up cross-sectional view of the end effector 5600 with the anvil 5602 in a closed position. In the closed position, the anvil 5602 can compress the tissue 5618 and the tissue compensator 5610 against the staple cartridge 5606. In some cases, only a portion of the end effector 5600 may be encapsulating tissue 5618. In the region of the end effector 5600 that envelopes the tissue 5618, the tissue compensator 5610 may be compressed a greater amount 5624 than in regions that do not envelop the tissue 5618, where the tissue compensator 5618 may remain uncompressed 5626 or less compressed. In the more compressed region 5624, the series of conductors 5620 will also be compressed, while in the uncompressed region 5626, the series of conductors 5620 will be spaced farther apart. Thus, the conductivity, resistance, capacitance, and/or some other electrical property between the series of conductors 5620 can indicate which regions of the end effector 5600 include tissue.

Fig. 102A and 102B illustrate an embodiment of an end effector 5650 that includes a tissue compensator 5660 that further includes a conductor 5662 embedded therein. The end effector 5650 includes a first jaw member or anvil 5652 that is pivotably coupled to a second jaw member 5654. Second jaw member 5654 is configured to receive a staple cartridge 5656 therein. In some embodiments, the end effector 5650 further comprises a tissue compensator 5660 removably positioned on the anvil 5652 or staple cartridge 5656.

FIG. 102A illustrates a cross-sectional view of a tissue compensator 5660 removably positioned on a staple cartridge 5656. The cross-sectional view shows a conductor 5670 embedded within the material comprising the tissue compensator 5660. Each of the conductors 5672 is coupled to a conductive wire 5672. Conductive line 5672 allows a series of conductors 5672 to communicate with a microprocessor, such as microprocessor 1500. Conductor 5672 may include a conductive element, an electronic circuit, a microprocessor, or any combination thereof.

Fig. 102A shows a close-up side view of the end effector 5650 with the anvil 5652 in a closed position. In the closed position, the anvil 5652 can compress the tissue 5658 and the tissue compensator 5660 against the staple cartridge 5656. A conductor 5672 embedded within the tissue compensator 5660 is operable to apply current pulses 5674 of a predetermined frequency to the tissue 5658. The same or another conductor 5672 may detect the response of tissue 5658 and transmit this response to a microprocessor or microcontroller located in the instrument. The response of tissue 5658 to electrical pulse 5674 may be used to determine characteristics of tissue 5658. For example, the galvanic response of tissue 5658 is indicative of the water content of tissue 5658. As another example, measurements of electrical impedance in tissue 5658 can be used to determine the conductivity of tissue 5648, which is indicative of tissue type. Other characteristics that may be determined include, by way of example and not limitation: oxygen content, salinity, density, and/or the presence of certain chemicals. By combining data from several sensors, other characteristics may be determined, such as blood flow rate, blood type, presence of antibodies, and so forth.

Fig. 103 illustrates an embodiment of a staple cartridge 5706 and a tissue compensator 5710 wherein the staple cartridge 5706 provides power to the conductive element 5720 comprising the tissue compensator 5710. As shown, the staple cartridge 5706 includes electrical contacts 5724 in the form of patches, spokes, lugs, or some other raised configuration. The tissue compensator 5710 includes a wire mesh or solid contact points 5722 that can be electrically coupled to the contacts 5724 on the staple cartridge 5706.

Fig. 104A and 104B illustrate embodiments of a staple cartridge 5756 and a tissue compensator 5760, wherein the staple cartridge provides power to the conductive element 5710 that comprises the tissue compensator 5770. As shown in fig. 104A, the tissue compensator 5760 comprises projections or tabs 5772 configured to contact the staple cartridge 5756. The tabs 5772 may contact and attach to electrical contacts (not shown) on the staple cartridge 5756. The tabs 5772 also include break points 5774 positioned in the line of conductive elements 5770 that make up the tissue compensator 5760. When the tissue compensator 5760 is compressed, such as when the anvil is in a closed position relative to the staple cartridge 5756, the fracture point 5774 will fracture, thereby allowing the tissue compensator 5756 to separate from the staple cartridge 5756. Fig. 104B shows another embodiment employing a break point 5774 positioned in the tab 5772.

105A and F8B illustrate an embodiment of an end effector 5800 that includes a position sensing element 5824 and a tissue compensator 5810. The end effector 5800 comprises a first jaw member or anvil 5802 that is pivotally coupled to a second jaw member 5804 (not shown). Second jaw member 5804 is configured to receive a staple cartridge 5806 (not shown) therein. In some embodiments, the end effector 5800 further comprises a tissue compensator 5810 removably positioned on the anvil 5802 or staple cartridge 5806.

Fig. 105A illustrates an anvil 5804 portion of an end effector 5800. In some embodiments, the anvil 5804 includes a position sensing element 5824. The position sensing elements 5824 may include, for example, electrical contacts, magnets, RF sensors, and the like. The position sensing elements 5824 may be positioned in strategic locations (e.g., corner points where the tissue compensator 5810 will be attached) or along the tissue-facing surface of the anvil 5802. In some embodiments, the tissue compensator 5810 can comprise a position indicating element 5820. The position indicating elements 5820 may be positioned in positions corresponding to the position sensing elements 5824 on the anvil 5802, or in a proximal position, or in an overlapping position. The tissue compensator 5810 optionally further comprises a layer of conductive elements 5812. The layer of conductive elements 5812 and/or the position indicating elements 5820 may be electrically coupled to conductive lines 5822. Conductive line 5822 may provide communication with a microprocessor (e.g., microprocessor 1500).

Fig. F8B illustrates an embodiment of the position sensing element 5824 and the position indicating element 5820 in operation. When the tissue compensator 5810 is positioned, the anvil 5802 can sense 5826 that the tissue compensator 5810 is properly positioned. When the tissue compensator 5810 is misaligned or missing completely, the anvil 5802 (or some other component) may sense 5826 that the tissue compensator 5810 is misaligned. If the misalignment is above a threshold amount, an alert may be signaled to an operator of the instrument and/or the functionality of the instrument may be disabled to prevent the staples from being fired.

In fig. 105A and 105B, the position sensing element 5824 is shown by way of example only as part of the anvil 5804. It should be understood that the position sensing elements 5824 may alternatively or additionally be positioned on the staple cartridge 5806. It should also be understood that the positions of the position sensing element 5824 and the position indicating element 5820 may be reversed such that the tissue compensator 5810 is operable to indicate whether it is properly aligned.

106A and F9B illustrate an embodiment of an end effector 5850 that includes a position sensing element 5874 and a tissue compensator 5860. The end effector 5850 includes a first jaw member or anvil 5852 that is pivotally coupled to a second jaw member 5854 (not shown). Second jaw member 5854 is configured to receive a staple cartridge 5856 (not shown) therein. In some embodiments, the end effector 5850 further comprises a tissue compensator 5860 removably positioned on the anvil 5852 or staple cartridge 5856.

Fig. 106A illustrates an anvil 5852 portion of an end effector 5850. In some embodiments, the anvil 5854 includes a series of conductive elements 5474. The series of conductive elements 5474 can include, for example, electrical contacts, magnets, RF sensors, and the like. A series of conductive elements 5474 are arranged along the length of the tissue-facing surface of the anvil 5852. In some embodiments, the tissue compensator 5860 can comprise a layer of conductive elements 5862, wherein the conductive elements comprise wire grids or wire meshes. The layer of conductive elements 5862 may be coupled to conductive wires 5876. Conductive line 5862 may provide communication with a microprocessor (e.g., microprocessor 1500).

Fig. 106A illustrates an embodiment in which the conductive elements 5474 and the conductive element 5862 layers of the anvil 5852 are operable to indicate whether the tissue compensator 5860 is misaligned or missing. As shown, a series of conductive elements 5874 are operable to electrically couple with the layer of conductive elements 5862. When the tissue compensator 5860 is misaligned or missing, the electrical coupling will be incomplete. If the misalignment is above a threshold amount, an alert may be signaled to an operator of the instrument and/or the functionality of the instrument may be disabled to prevent the staples from being fired.

It should be understood that a series of conductive elements 5874 may additionally or alternatively be positioned on staple cartridge 5856. It should also be understood that any of the anvil 5852, staple cartridge 5856, and/or tissue compensator 5860 can be operable to indicate misalignment of the tissue compensator 5860.

Fig. 107A and 107B illustrate an embodiment of a staple cartridge 5906 and a tissue compensator 5910 operable to indicate the position of a cutting member or knife bar 280. FIG. 107A is a top down view of a staple cartridge 5906 having a tissue compensator 5920 disposed on an upper surface 5916 thereof. The staple cartridge 5906 further includes a cartridge channel 5918 operable to receive a cutting member or knife bar 280. For clarity, fig. 107A shows only the conductive element 5922 layers of the tissue compensator 5910. As shown, the layer of conductive elements 5922 includes an eccentrically positioned elongate section 5930. The elongate section 5930 is coupled to the conductive wire 5926. The conductive line 5926 allows the layer of conductive elements 5922 to communicate with a microprocessor, such as microprocessor 1500. The layer of conductive elements 5922 also includes a horizontal element 5932 coupled to the elongate section 5930 and spanning the width of the tissue compensator 5910 and thus across the path of the knife bar 280. As the knife bar 280 advances, it will sever the horizontal element 5932 and thereby change the electrical properties of the layer of conductive element 5922. For example, advancement of the knife bar 280 may change the resistance, capacitance, conductivity, or some other electrical property of the layer of conductive elements 5922. As each conductive element 5932 is severed by the knife bar 280, a change in the electrical properties of the layers of conductive element 5922 will indicate the position of the knife bar 280.

Fig. 107B shows an alternative configuration of the layers of the conductive element 5922. As shown, the layer of conductive elements 5922 includes elongated segments 5934 located on either side of the cartridge passage 5918. The layer of conductive elements 5922 also includes a horizontal element 5936 coupled to the two lengthwise segments 5934, thereby traversing the path of the knife bar 280. As knife bar 280 advances, for example, the resistance between the knife bar and horizontal member 5396 may be measured and used to determine the position of knife bar 280. Other configurations of the layers of the conductive element 5922 can be used to achieve the same result, for example, any of the configurations shown in fig. 98A-102B. For example, the layer of conductive elements 5922 may include a wire mesh or wire grid such that when the knife bar 280 is advanced, it can cut through the wire mesh and thereby change the conductivity of the wire mesh. This change in conductivity may be used to indicate the position of knife bar 280.

Other uses of the layer of conductive elements 5922 are contemplated. For example, a certain resistance may be created in the layer of conductive elements 592, or a binary ladder of resistors or conductors may be implemented such that simple data may be stored in the tissue compensator 5910. When either of the anvil and/or the staple cartridge is electrically coupled with the layer of conductive elements 5922, this data may be extracted from the tissue compensator 5910 by the conductive elements in the anvil and/or the staple cartridge. The data may represent, for example, a serial number, a "valid use" date, and so forth.

Polarity of Hall magnet for detecting mis-loading bin

Fig. 108 illustrates one embodiment of an end effector 6000 including a magnet 6008 and a hall effect sensor 6010, wherein a detected magnetic field 6016 may be used to identify a staple cartridge 6006. The end effector 6000 is similar to the end effector 300 described above. End effector 6000 includes a first jaw member or anvil 6002 that is pivotally coupled to a second jaw member or elongate channel 6004. The elongate channel 6004 is configured to support a staple cartridge 6006 therein. The staple cartridge 6006 is similar to staple cartridge 304 described above. The anvil 6002 also includes a magnet 6008. The staple cartridge 6006 also includes a hall effect sensor 6010 and a processor 6012. The hall effect sensor 6010 is operable to communicate with the processor 6012 through a conductive coupling 6014. A hall effect sensor 6010 is positioned within the staple cartridge 6006 to operably couple with the magnet 6008 when the anvil 6002 is in the closed position. The hall effect sensor 6010 is operable to detect a magnetic field 6016 generated by the magnet 6008. The polarity of the magnetic field 6016 may be one of north or south, depending on the orientation of the magnets 6008 within the anvil 6002. In the illustrated embodiment of fig. 108, the magnet 6008 is oriented with its south pole toward the staple cartridge 6006. The hall effect sensor 6010 is operable to detect a magnetic field 6016 generated by a south pole. The staple cartridge 6006 can be identified as having a first type if the hall effect sensor 6010 detects the south magnetic pole.

FIG. 109 illustrates one embodiment of an end effector 6050 comprising a magnet 6058 and a Hall effect sensor 6060 wherein a detected magnetic field 6066 can be used to identify a staple cartridge 6056. End effector 6050 includes a first jaw member or anvil 6052 that is pivotally coupled to a second jaw member or elongate channel 6054. The elongate channel 6054 is configured to support a staple cartridge 6056 therein. Anvil 6052 also includes magnets 6058. The staple cartridge 6056 also includes a hall effect sensor 6060 that communicates with a processor 6062 via a conductive coupling 6064. The hall effect sensor 6060 is positioned such that it will operably couple with the magnet 6058 when the anvil 6052 is in the closed position. The hall effect sensor 6060 is operable to detect a magnetic field 6066 generated by a magnet 6058. In the illustrated embodiment, the magnet 6058 is oriented with its north pole facing the staple cartridge 6056. Hall effect sensor 6060 is operable to detect magnetic field 6066 generated by the north pole. If the Hall effect sensor 6060 detects a north magnetic pole, the staple cartridge 6056 may be identified as being of the second type.

It can be appreciated that the second staple cartridge 6056 of FIG. 109 can replace the first staple cartridge 6006 of FIG. 108 and vice versa. In fig. 108, the second type staple cartridge 6056 will be operable to detect the north magnetic pole, but will instead detect the south magnetic pole. In such a case, the end effector 6000 will identify the staple cartridge 6056 as being of the second type. If the end effector 6000 does not desire the second type of staple cartridge 6056, the operator of the instrument may be alerted and/or the functions of the instrument will be disabled. Additionally or alternatively, the type of staple cartridge 6056 can be used to identify certain parameters of the staple cartridge 6056, such as the length of the cartridge and/or the height and length of the staples.

Similarly, as shown in FIG. 109, a first type staple cartridge 6006 can replace the second staple cartridge 6056. The first type of staple cartridge 6006 would be able to operate to detect the south magnetic pole, but would instead detect the north magnetic pole. In this instance, the end effector 6050 will identify the staple cartridge 6006 as being of the first type.

Fig. 110 shows a graph 6020 of the voltage 6022 detected by a hall effect sensor positioned in the distal tip of a staple cartridge, e.g., as shown in fig. 108 and 109, in response to the distance or gap 6024 between a magnet positioned in the anvil and the hall effect sensor in the staple cartridge, e.g., as shown in fig. 108 and 109. As shown in FIG. 110, when the magnet in the anvil is oriented with its north pole toward the staple cartridge, the voltage will tend to approach a first value as the magnet approaches the Hall effect sensor; when the magnet is oriented with its south pole toward the staple cartridge, the voltage will tend to approach a second, different value. The measured voltage may be used by the instrument to identify the staple cartridge.

Figure 111 illustrates one embodiment of a housing 6100 of a surgical instrument that includes a display 6102. Housing 6100 is similar to housing 12 described above. Display 6102 may be operable to communicate information to an operator of the instrument that, for example, a staple cartridge coupled to the end effector is not suitable for the present application. Additionally or alternatively, the display 6102 can display parameters of the staple cartridge, such as the length of the cartridge and/or the height and length of the staples.

FIG. 112 illustrates one embodiment of a staple holder 6160 that includes a magnet 6162. The staple holder 6160 is operably coupled to the staple cartridge 6156 and functions to prevent staples from exiting the staple cartridge 6156. The staple holder 6160 can remain in place as the staple cartridge 6156 is applied to the end effector. In some embodiments, the staple holder 6160 includes a magnet 6162 positioned in a distal region of the staple holder 6160. The anvil of the end effector can comprise a hall effect sensor operable to couple with the magnet 6162 of the staple holder 6160. The hall effect sensor is operable to detect characteristics of the magnet 6162, such as magnetic field strength and magnetic polarity. The magnetic field strength can be varied by, for example, disposing the magnet 6162 at different locations and/or depths on or in the staple holder 6160 or by selecting a magnet 6162 having a different composition. Different characteristics of the magnet 6162 can be used to identify different types of staple cartridges.

Fig. 113A and 113B illustrate one embodiment of an end effector 6200 that includes a sensor 6208 for identifying different types of staple cartridges 6206. The end effector 6200 includes a first jaw member or anvil 6202 that is pivotally coupled to a second jaw member or elongate channel 6204. The elongate channel 6204 is configured to support a staple cartridge 6206 therein. The end effector 6200 also includes a sensor 6208 positioned in the proximal region. The sensor 6208 can be any of an optical sensor, a magnetic sensor, an electrical sensor, or any other suitable sensor.

The sensor 6208 is operable to detect characteristics of the staple cartridge 6206 and thereby identify the staple cartridge 6206 type. Fig. 113B shows an example in which the sensor 6208 is an optical emitter and detector 6210. The body of the staple cartridge 6206 may be a different color such that the color identifies the staple cartridge 6206 type. The optical emitter and detector 6210 can be operable to interrogate the color of the staple cartridge 6206 body. In the illustrated embodiment, the optical emitter and detector 6210 can detect white 6212 by receiving reflected light of moderate intensity in the red, green, and blue spectrums. The optical emitter and detector 6210 may detect the red 6214 by receiving very little reflected light in the green and blue spectrums while receiving light of higher intensity in the red spectrum.

Alternatively or in addition, an optical emitter and detector 6210 or another suitable sensor 6208 can interrogate and identify some other symbol or indicia on the staple cartridge 6206. The symbol or indicia may be any of a bar code, a shape or character, a color-coded logo, or any other suitable indicia. The information read by the sensor 6208 may be communicated to a microcontroller, e.g., microcontroller 1500, in the surgical device 10. The microcontroller 1500 can be configured to communicate information about the staple cartridge 6206 to an operator of the instrument. For example, the identified staple cartridge 6206 may not be suitable for a given application; in this case, the operator of the instrument may be notified and/or the function of the instrument is not appropriate. In such a case, the microcontroller 1500 can optionally be configured to disable the functionality of the surgical instrument. Alternatively or in addition, the microcontroller 1500 can be configured to notify an operator of the surgical instrument 10 of parameters of the identified staple cartridge 6206 type, such as the length of the staple cartridge 6206, or information about the staples (e.g., height and length).

Smart bin wakeup operation and data retention

In one embodiment, the surgical instrument described herein includes short circuit protection techniques for the sensors and/or electronic components. To enable such sensors and other electronics, power and data signals are transmitted between modular components of the surgical instrument. During assembly of the modular sensor components, the electrical conductors connected for transmitting power and data signals between the connected components are typically exposed.

Fig. 114 is a partial view of an end effector 7000 having electrical conductors 7002, 7004 for transmitting power and data signals between connection components of a surgical instrument according to one embodiment. These electrical conductors 7002, 7004 may become short circuited and thus damage critical system electronic components. Fig. 115 is a partial view of the end effector 7000 shown in fig. 114, showing the sensors and/or electronic components 7005 positioned in the end effector. Referring now to fig. 114 and 115, in various embodiments of surgical instruments disclosed throughout this disclosure, the present disclosure utilizes electronic sensors to provide feedback regarding compressibility and thickness of tissue. The modular architecture will enable the configuration of custom modular shafts to employ task specific techniques. To enable the sensors and other electronic circuit components in the surgical instrument, power and data signals need to be transmitted between the second circuit, including the modular sensor and/or electronic circuit components 7005. During assembly of the modular sensor and/or electronic component 7005, the electrical conductors 7002, 7004 are exposed such that when connected, they transmit power and data signals between the connected sensor and/or electronic component 7005. Because these electrical conductors 7002, 7004 may become short-circuited during assembly and thus damage other system electronic circuits, various embodiments of the surgical instruments described herein include short-circuit protection techniques for the sensors and/or the electronic components 7005.

In one embodiment, the present disclosure provides a short protection circuit 7012 for the sensor and/or electronic component 7005 of the second circuit of the surgical instrument. Figure 116 is a block diagram of a surgical instrument electronics subsystem 7006 including short circuit protection circuits 7012 for the sensors and/or electronic components 7005 according to one embodiment. The main power supply circuit 7010 is connected to a main circuit including a microprocessor and other electronic components 7008 (hereinafter, the processor 7008) through main power supply terminals 7018, 7020. The main power supply circuit 7010 is also connected to a short-circuit protection circuit 7012. The short circuit protection circuit 7012 is coupled to a supplemental power circuit 7014, which supplemental power circuit 7014 supplies power to the sensors and/or electronic components 7005 through the electrical conductors 7002, 7004.

To reduce damage to the processor 7008 connected to the main power supply terminals 7018, 7020, a self-isolating/recovering short circuit protection circuit 7012 is provided during a short circuit between the electrical conductors 7002, 7004 feeding the power terminals of the sensor and/or electronic components 7005. In one embodiment, the short circuit protection circuit 7012 may be implemented by coupling a supplemental power circuit 7014 to the main power circuit 7010. In the event that the supplemental power circuit 7014 power conductors 7002, 7004 are shorted, the supplemental power circuit 7014 itself is isolated from the main power circuit 7010 to avoid damage to the processor 7008 of the surgical instrument. Therefore, when a short circuit occurs in the electrical conductors 7002, 7004 of the supplementary power supply circuit 7014, there is virtually no effect on the processor 7008 and other electronic circuit components coupled to the main power supply terminals 7018, 7020. Therefore, if a short circuit occurs between the electrical conductors 7002, 7004 of the supplementary power supply circuit 7014, the main power supply circuit 7010 is not affected and remains able to efficiently supply power to the protected processor 7008, so that the processor 7008 can monitor the short circuit state. When the short circuit between the electrical conductors 7002, 7004 of the supplemental power circuit 7014 is corrected, the supplemental power circuit 7014 reengages the primary power circuit 7010 and may be used again to supply power to the sensor member 7005. The short-circuit protection circuit 7012 may also be monitored to indicate one or more short-circuit conditions to an end user of the surgical instrument. The short-circuit protection circuit 7012 may also be monitored to lockout firing of the surgical instrument when a short-circuit event is indicated. Multiple supplemental protection circuits may be networked together to isolate, monitor, or protect other circuit functions.

Thus, in one aspect, the present disclosure provides a short circuit protection circuit 7012 for the electrical conductors 7002, 7004 or other elements of the surgical instrument in the end effector 7000 (fig. 114 and 115). In one embodiment, the short-circuit protection circuit 7012 employs a supplemental self-isolating/restoring power supply circuit 7014 coupled to a main power supply circuit 7010. The short-circuit protection circuit 7012 may be monitored to indicate one or more short-circuit conditions to an end user of the surgical instrument. In the event of a short circuit, the short protection circuit 7012 may be used to lockout the surgical instrument from being fired or to lockout other device operations. A plurality of other supplemental protection circuits may be networked together to isolate, monitor, or protect other circuit functions.

Fig. 117 is a short circuit protection circuit 7012 that includes a supplemental power circuit 7014 coupled to a main power circuit 7010, according to one embodiment. The main power circuit 7010 includes a transformer 7023(X1) coupled to a full wave rectifier 7025 implemented with diodes 91-94. Full wave rectifier 7025 is coupled to voltage regulator 7027. The Output (OUT) of the voltage regulator 7027 is coupled to output terminals 7018, 7020(OP1) of the main power supply circuit 7010 and the supplementary power supply circuit 7014. Input capacitor C1 filters the input voltage in voltage regulator 7027 and one or more capacitors C2 filters the output of voltage regulator 7027.

In the embodiment shown in fig. 117, the supplemental power circuit 7014 includes a pair of transistors T1, T2 configured to control a power output OP2 between the electrical conductors 7002, 7004. During normal operation where the electrical conductors 7002, 7004 are not shorted, the output OP2 supplies power to the sensor member 7005. Once the transistors T1 and T2 turn on (activate) and begin to conduct current, the current from the output of the voltage regulator 7027 is shunted by the first transistor T1 so that no current flows through R1 and i _R10. The output voltage + V of the voltage regulator is applied to the node so as to supplement that of the power supply circuit 7014The output voltage OP2 is V_n+ V, and the first transistor T1 drives current to flow through the output terminal 7002 to the sensor part 7005, where the output terminal 7004 is a current return path. Output current i_R5Turns through R5 to drive output indicator LED 2. The current flowing through the LED2 is i_R5. As long as the node voltage V_nAbove the threshold required to turn on (activate) the second transistor T2, the supplemental power supply circuit 7014 acts as a power supply circuit feeding the sensor and/or electronic components 7005.

When the electrical conductors 7002, 7004 of the second circuit are short-circuited, the node voltage V_nFalls to ground or zero and the second transistor T2 turns off and stops conducting, which turns off the first transistor T1. When the first transistor T1 is turned off, the output voltage + V of the voltage regulator 7027 results in a current i _R1Flows through the short indicator LED1 and to ground via a short between the electrical conductors 7002, 7004. Therefore, no current flows through R5, and i_R50A and + V_OP20V. The supplementary power circuit 7014 itself is isolated from the main power circuit 7010 until the short circuit is removed. During a short circuit, only the short indicator LED1 is powered, while the output indicator LED2 is not powered. When the short circuit between the electrical conductors 7002, 7004 is removed, the node voltage V_nRising until T2 turns on and then T1 turns on. When T1 and T2 are turned on (biased to a conductive state, such as saturation) until the node voltage V_nTo reach + V_OP2When so, and the supplementary power circuit 7014 resumes its power supply function for the sensor part 7005. Once the supplemental power circuit 7014 resumes its power function, the short indicator LED1 turns off and the output indicator LED2 turns on. This cycle is repeated if another short circuit occurs between the conductors 7002, 7004 of the supplemental power circuit 7014.

In one embodiment, a sample rate monitor is provided to achieve power reduction by limiting the sampling rate and/or duty cycle of the sensors when the surgical instrument is in a non-sensing state. Fig. 118 is a block diagram of a surgical instrument electronics subsystem 7022 including a sample rate monitor 7024 to achieve power reduction by limiting the sample rate and/or duty cycle of the sensors and/or electronic components 7005 of the second circuit when the surgical instrument is in a non-sensing state, according to one embodiment. As shown in fig. 118, the surgical instrument electronics subsystem 7022 includes a processor 7008 coupled to a main power circuit 7010. The main power supply circuit 7010 is coupled to a sample rate monitor circuit 7024. The supplemental power circuit 7014 is coupled to a sample rate monitor 7024 when the sensor and/or electronic components 7005 are powered through the electrical conductors 7002, 7004. The main circuit, including the processor 7008, is coupled to a device state monitor 7026. In various embodiments, the surgical instrument electronics subsystem 7022 provides real-time feedback regarding compressibility and thickness of tissue using sensors and/or electronic components 7005 as described herein previously. The modular architecture of the surgical instrument enables the configuration of a custom modular shaft to employ functional task specific techniques. To enable such additional functionality, electronic connection points and components are employed to transmit power and signals between modular components of the surgical instrument. An increase in the number of sensors and/or electronic components 7005 will increase the power consumption of the surgical instrument system 7022 and thus various techniques for reducing the power consumption of the surgical instrument system 7022 are needed.

In one embodiment, to reduce power consumption, a surgical instrument configured with the sensor and/or electronic component 7005 (second circuit) includes a sample rate monitor 7024 that can be implemented as a hardware circuit or software technique to reduce the sample rate and/or duty cycle of the sensor and/or electronic component 7005. The sample rate monitor 7024 operates in conjunction with a device state monitor 7026. The device status monitor 7026 senses the status of various electrical/mechanical subsystems of the surgical instrument. In the embodiment shown in fig. 118, the device state monitor 7026 senses whether the state of the end effector is in an unclamped (state 1), clamping (state 2), or clamped (state 3) operating state.

The sample rate monitor 7024 sets the sample rate and/or duty cycle of the sensor component 7005 based on the state of the end effector as determined by the device state monitor 7026. In one aspect, the sample rate monitor 7024 may set the duty cycle to about 10% when the end effector is in state 1, about 50% when the end effector is in state 2, or about 20% when the end effector is in state 3. In various other embodiments, the duty cycle and/or sampling rate set by the sampling rate monitor 7024 may take a range of values. For example, in another aspect, the sample rate monitor 7024 may set the duty cycle to about 5% to about 15% when the end effector is in state 1, about 45% to about 55% when the end effector is in state 2, or about 15% to about 25% when the end effector is in state 3. In various other embodiments, the duty cycle and/or sampling rate set by the sampling rate monitor 7024 may take on additional ranges of values. For example, in another aspect, the sample rate monitor 7024 may set the duty cycle to about 1% to about 20% when the end effector is in state 1, about 20% to about 80% when the end effector is in state 2, or about 1% to about 50% when the end effector is in state 3. In various other embodiments, the duty cycle and/or sampling rate set by the sampling rate monitor 7024 may take on additional ranges of values.

In one aspect, the sample rate monitor 7024 may be implemented by generating supplemental circuitry/software coupled to the main circuitry/software. When the supplemental circuitry/software determines that the surgical instrument system 7022 is in a non-sensing state, the sample rate monitor 7024 causes the sensors and/or the electronic components 7005 to enter a reduced adoption or duty cycle mode, thereby reducing the power load on the primary circuit. The main power supply circuit 7010 will still be able to supply power efficiently so that the protected processor 7008 of the main circuit can monitor the status. When the surgical instrument system 7022 enters a state where more stringent sensing activity is required, the sample rate monitor 7024 increases the supplemental circuit sample rate or duty cycle. The circuit may employ a mixture of integrated circuits, solid state components, microprocessors, or firmware. The reduced sample rate or duty cycle mode circuitry may also be monitored to indicate status to an end user of the surgical instrument system 7022. Circuitry/software may also be monitored to lockout the firing or function of the device when the device is in a power saving mode.

In one embodiment, the sample rate monitor 7024 hardware circuitry or software techniques may reduce the sample rate and/or duty cycle for the sensors and/or the electronic components 7005 to reduce the power consumption of the surgical instrument. The reduced sampling rate or duty cycle pattern may be monitored to indicate one or more conditions to an end user of the surgical instrument. The protection circuit/software may be configured to lockout the surgical instrument from being fired or otherwise operated if a reduced sampling rate and/or duty cycle condition occurs in the surgical instrument.

In one embodiment, the present disclosure provides an over-current and/or over-voltage protection circuit for sensors and/or electronic components in a surgical instrument. Fig. 119 is a block diagram of a surgical instrument electronics subsystem 7028 including an over current/over voltage protection circuit 7030 for sensors and/or electronic components 7005 of a second circuit of a surgical instrument, according to one embodiment. In various embodiments, the surgical instrument electronics subsystem 7028 provides real-time feedback regarding compressibility and thickness of tissue using the sensors and/or electronic components 7005 of the second circuit, as described herein previously. The modular architecture of the surgical instrument enables the configuration of a custom modular shaft to employ functional task specific techniques. To enable the sensors and/or electronic components 7005, additional electronic connection points and components are added to transfer power and signals between the modular components. These additional conductors for the sensors and/or electronic components 7005 from the modular sections may be shorted and/or damaged, thereby resulting in greater current consumption, which may damage the fragile processor 7008 circuitry and/or other electronic components of the main circuitry. In one embodiment, the over current/voltage protection circuit 7030 protects the conductors for the sensors and/or electronic components 7005 on the surgical instrument with a supplemental self-isolating/restoring circuit 7014 coupled to the main power circuit 7010. The operation of one embodiment of the supplemental self-isolation/restore circuit 7014 has been described in conjunction with fig. 117 and will not be repeated here for the sake of brevity and clarity of the present disclosure.

In one embodiment, to reduce electrical damage during sensing of high current consumption in a surgical instrument, the electronics subsystem 7028 of the surgical instrument includes an over current/over voltage protection circuit 7030 for the conductors of the sensors and/or the electronic components 7005. The over current/voltage protection circuit 7030 may be implemented by creating a supplemental circuit coupled to the main power circuit 7010. To the extent that the supplemental circuit electrical conductors 7002, 7004 are subjected to higher than expected current levels, the over current/over voltage protection circuit 7030 isolates the current from the main power circuit 7010 to avoid damage. The main power circuit 7010 will still be able to supply power efficiently so that the protected main processor 7008 can monitor the status. When the greater current draw of the supplemental power circuit 7014 is corrected, the supplemental power circuit 7014 reengages the main power circuit 7010 and is available to supply power to the sensors and/or the electronic components 7005 (e.g., the second circuit). The over current/voltage protection circuit 7030 may employ a mixture of integrated circuits, solid state components, microprocessors, firmware, circuit breakers, fuses, or PTC (positive temperature coefficient) type technologies.

In various embodiments, the over current/voltage protection circuit 7030 may also be monitored to indicate an over current/voltage condition to the end user of the device. The over current/voltage protection circuit 7030 may also be monitored to lockout the firing of the surgical instrument when an over current/voltage condition event is indicated. The over current/voltage protection circuit 7030 may also be monitored to indicate one or more over current/voltage bank conditions to the end user of the device. The over current/voltage protection circuit 7030 can lockout the surgical instrument from being fired or other operation of the surgical instrument if an over current/voltage condition occurs in the device.

Fig. 120 is an over current/over voltage protection circuit 7030 for a sensor and electronics 7005 (fig. 119) of a second circuit of a surgical instrument according to one embodiment. During a hard SHORT (SHORT), the over current/voltage protection circuit 7030 provides a current path at the output of the over current/voltage protection circuit 7030 and also through a stray inductance L_StrayDriven bypass capacitor C_{Bypass path}Providing a path for subsequent current flow.

In one embodiment, the over current/voltage protection circuit 7030 includes a current limit switch 7032 that has an automatic reset feature. The current limit switch 7032 includes a current sense resistor RCS coupled to the amplifier a. When the amplifier a senses an inrush current above a predetermined threshold, the amplifier activates the circuit breaker CB to open the current path, thereby interrupting the inrush current. In one implementation, the current limit switch 7032 with the automatic reset feature may be implemented using a MAX1558 integrated circuit from Maxim. The current limit switch 7032 has an automatic reset feature. If switch 7032 shorts for more than 20ms, the auto-reset feature latches the switch, saving system power. The SHORT circuit output (SHORT) is then tested to determine when the SHORT circuit has been removed to automatically restart the channel. The low sleep supply current (45 μ A) and standby current (3 μ A) maintain battery power in the surgical instrument. The current limit switch 7032 with the automatic reset safety feature keeps the surgical instrument protected. Built-in thermal overload protection limits power dissipation and junction temperature. An accurate, programmable current limiting circuit protects the input source from overload and short circuit conditions. The 20ms fault blanking enables the circuit to ignore transient faults, such as those generated when hot swapping capacitive loads, thereby avoiding providing false alarms to the host system. In one embodiment, the current limit switch 7032 with automatic reset feature also provides a reverse current protection circuit to prevent current from flowing from the output to the input when the switch 7032 is open.

In one embodiment, the present disclosure provides reverse polarity protection for sensors and/or electronic components in a surgical instrument. Fig. 121 is a block diagram of a surgical instrument electronics subsystem 7040 having a reverse polarity protection circuit 7042 for sensors and/or electronic components 7005 of the second circuit, according to one embodiment. Reverse polarity protection is provided for exposed leads (electrical conductors 7002, 7004) of the surgical instrument with a supplemental self-isolating/restoring circuit, referred to herein as a supplemental power circuit 7014, coupled to the main power circuit 7010. The reverse polarity protection circuit 7042 may be monitored to indicate one or more reverse polarity states to an end user of the device. If reverse polarity is applied to the device, the protection circuit 7042 may latch the device from being fired or latching other device critical operations.

In various embodiments, the surgical instruments described herein utilize sensors and/or electronic components 7005 to provide real-time feedback regarding compressibility and thickness of tissue. The modular architecture of the surgical instrument enables customization of the configuration of the modular shaft to employ task-specific techniques. Power and data signals are transmitted between the modular components for the sensors and/or electronic components 7005. During assembly of the modular components, the electrical conductors that are connected for transmitting power and data signals between the connected components are typically exposed electrical conductors. The conductors may be energized with opposite polarity.

Thus, in one embodiment, the surgical instrument electronics subsystem 7040 is configured to reduce electrical damage during sensing of reverse polarity coupling 7044 application in a surgical instrument. The surgical instrument electronics subsystem 7040 employs a polarity protection circuit 7042 inline with the exposed electrical conductors 7002, 7004. In one embodiment, the polarity protection circuit 7042 may be implemented by generating a supplemental power circuit 7014 coupled to the main power circuit 7010. In the event that the supplemental power circuit 7014 electrical conductors 7002, 7004 are powered by reverse polarity, they isolate power from the main power circuit 7010 to avoid damage. The main power supply circuit 7010 will still be able to supply power efficiently so that the protected processor 7008 of the main circuit can monitor the status. When the reverse polarity of the supplemental power circuit 7014 is corrected, the supplemental power circuit 7014 reengages the primary power circuit 7010 and is available to supply power to the secondary circuit. The reverse polarity protection circuit 7042 may also be monitored to indicate the reverse polarity status to the end user of the device. The reverse polarity protection circuit 7042 may also be monitored to lockout the firing of the device if a reverse polarity event is indicated.

Figure 122 is a reverse polarity protection circuit 7042 for a sensor and/or electronic component 7005 of a second circuit of a surgical instrument according to one embodiment. During normal operation, the relay switch S₁Battery voltage B of main power circuit 7010 (fig. 121) including output contacts in Normally Closed (NC) position₁Is applied to V coupled to a second circuit_{Output of}. Diode D₁Preventing current flow through relay switch S₁Coil 7046 (inductor). When battery B₁When the polarity of (a) is reversed,diode D₁Conducting electricity and current flowing through relay switch S ₁7046, thereby to relay switch S₁Supplying power to set the output contact to a Normally Open (NO) position and thereby couple the reverse voltage to V coupled to the second circuit_{Output of}The connection is broken. Once switched on and off S₁In NO position, from battery B₁The current of the positive terminal of the LED D flows through₃And R₁To avoid battery B₁And (6) short-circuiting. Diode D₂To clamp the diode against spikes generated by the coil 7046 during switching.

In one embodiment, the surgical instruments described herein utilize a sleep mode for sensors on a modular device to provide power reduction techniques. Fig. 123 is a block diagram of a surgical instrument electronics subsystem 7050 that implements power reduction using a sleep mode monitor 7052 for sensors and/or electronic components 7005, according to one embodiment. In one embodiment, the sensor for the second circuit and/or the sleep mode monitor 7052 of the electronic component 7005 may be implemented as a circuit and/or a software program to reduce power consumption of the surgical instrument. The sleep mode monitor 7052 protection circuitry may be monitored to indicate one or more sleep mode states to an end user of the device. The sleep mode monitor 7052 protection circuitry/software may be configured to lock the device from firing or being operated by the user if a sleep mode state occurs in the device.

In various embodiments, the surgical instruments described herein utilize electronic sensors 7005 to provide real-time feedback regarding compressibility and thickness of tissue. The modular architecture of the surgical instrument enables the surgical instrument to be configured with a custom modular shaft that employs task-specific techniques. To enable the sensors and/or electronic components 7005, additional electronic connection points and components may be employed to transmit power and data signals between the modular components. As the number of sensors and/or electronic components 7005 increases, the power consumption of the surgical instrument will increase, thereby requiring techniques for reducing the power consumption of the surgical instrument.

In one embodiment, the electronic subsystem 7050 includes sleep mode monitor 7052 circuitry and/or software for the sensor 7005 to reduce power consumption of the sensing surgical instrument. The sleep mode monitor 7052 may be implemented by generating a supplemental power circuit 7014 coupled to the main power circuit 7010. The device monitor 7054 monitors whether the surgical instrument is in a 1-unclamped state, a 2-clamping state, or a 3-clamped state. When the sleep mode monitor 7052 software determines that the surgical instrument is in the non-sensing state (1 ═ non-clamped state), the sleep mode monitor 7052 causes the sensors and/or electronic components 7005 of the second circuit to enter a sleep mode to reduce the power load on the main power circuit 7010. The main power supply circuit 7010 will still be able to supply power efficiently so that the protected processor 7008 of the main circuit can monitor the status. When the surgical instrument enters a state requiring sensor activity, the supplemental power circuit 7014 wakes up and reengages the primary power circuit 7010. The sleep mode monitor 7051 circuitry may employ a mixture of integrated circuits, solid state components, microprocessors, and/or firmware. The sleep mode monitor 7051 circuitry may also be monitored to indicate status to the end user of the device. The sleep mode monitor 7051 circuitry may also be monitored to latch the firing or function of the device when the device is in a power saving mode.

In one embodiment, the present disclosure provides protection against power loss of sensors and/or electronic components in a modular surgical instrument. Fig. 124 is a block diagram of a surgical instrument electronics subsystem 7060 that includes a temporary power loss circuit 7062 to provide protection against intermittent power loss of sensors and/or electronic components 7005 in a modular surgical instrument.

In various embodiments, the surgical instruments described herein utilize sensors and/or electronic components 7005 to provide real-time feedback regarding compressibility and thickness of tissue. The modular architecture of the surgical instrument enables the surgical instrument to be configured with a custom modular shaft that employs task-specific techniques. To enable the sensors and/or electronic components 7005, additional electronic connection points and components may be employed to transmit power and signals between the modular components. As the number of electrical connection points increases, the likelihood of the sensor and/or electronic component 7005 experiencing a short term intermittent power loss increases.

According to one embodiment, the temporary power loss circuit 7062 is configured to reduce device operational errors resulting from sensing short term intermittent power losses in the surgical instrument. The temporary power loss circuit 7062 is capable of delivering continuous power over a short period of time in the event of a disruption of power from the main power circuit 7010. The temporary power loss circuit 7062 may include capacitive elements, batteries, and/or other electronic elements capable of equalizing, detecting, or storing power.

As shown in fig. 124, the temporary power loss circuit 7062 may be implemented by generating supplemental circuitry/software coupled to the main circuitry/software. In the event that the supplemental circuitry/software experiences a sudden loss of power from the primary power source, the sensors and/or electronic components 7005 powered by the supplemental power circuit 7014 will not be affected for a short period of time. During a power loss, the supplemental power circuit 7014 may be powered up by a capacitive element, a battery, and/or other electronic components capable of equalizing or storing power. A temporary power loss circuit 7062, implemented in hardware or software, may also be monitored to lockout the firing or function of the surgical instrument when the device is in a power saving mode. A temporary power loss circuit 7062, implemented in hardware or software, may lockout the surgical instrument from being fired or operated if an intermittent power loss condition occurs in the surgical instrument.

Fig. 125 illustrates one embodiment of a temporary power loss circuit 7062 implemented as a hardware circuit. The temporary power loss circuit 7062 hardware circuitry is configured to reduce surgical instrument operational errors resulting from short term intermittent power losses. The temporary power loss circuit 7062 is capable of delivering continuous power over a short period of time in the event of a power interruption from the main power circuit 7010 (fig. 124). The temporary power loss circuit 7062 employs capacitive elements, batteries, and/or other electronic components capable of equalizing, detecting, or storing power. The temporary power loss circuit 7062 may be monitored to indicate one or more states to an end user of the surgical instrument. The temporary power loss circuit 7062 protects the circuit/software latchable device from being fired or operated if an intermittent power loss condition occurs in the surgical instrument.

In the illustrated embodiment, the temporary power loss circuit 7062 includes an analog switch integrated circuit U1. In one implementation, the analog switch integrated circuit U1 is a Single Pole Single Throw (SPST), low voltage, single source, CMOS analog switch, e.g., MAX4501 provided by Maxim. In one embodiment, the analog switch integrated circuit U1 is Normally Open (NO). In other embodiments, the analog switch integrated circuit U1 may be Normally Closed (NC). The input IN activates the NO analog switch 7064 through the standby "inverter capacitor" to connect the output of the boost DC-DC converter U3 to the input of the linear regulator U2. The output of the linear regulator U2 is coupled to the input of the DC-DC converter U3. Linear regulator U2 maximizes battery life by combining ultra low source current and low dropout voltage. In one embodiment, linear regulator U2 is a MAX882 integrated circuit provided by Maxim.

The battery is also coupled to the input of a boost DC-DC converter U3. The boost DC-DC converter U3 may be a compact, high efficiency, boost DC-DC converter with a built-in synchronous rectifier to improve efficiency and reduce size and cost by eliminating the need for external Schottky diodes. In one embodiment, the boost DC-DC converter U3 is a MAX1674 integrated circuit from Maxim.

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Fig. 126A and 126B illustrate perspective views of one embodiment of an end effector 10000 that includes a magnet 10008 and a hall effect sensor 10010 in communication with a processor 10012. The end effector 10000 is similar to the end effector 300 described above. The end effector includes a first jaw member or anvil 10002 that can be pivotally coupled to a second jaw member or elongate channel 10004. The elongate channel 10004 is configured to support a staple cartridge 10006 therein. The staple cartridge 10006 is similar to the staple cartridge 304 described above. The anvil 10008 can comprise a magnet 10008. The staple cartridge includes a hall effect sensor 10010 and a processor 10012. The hall effect sensor 10010 is operable to communicate with the processor 10012 through a conductive coupling 10014. The hall effect sensor 10010 is positioned within the staple cartridge 10006 to operably couple with the magnet 10008 when the anvil 10002 is in the closed position. The hall effect sensor 10010 can be configured to detect a change in the magnetic field surrounding the hall effect sensor 10010 caused by the movement or position of the magnet 10008.

Fig. 127 illustrates one embodiment of the operational dimensions associated with the operation of the hall effect sensor 10010. The first dimension 10020 is located between the bottom of the center of the magnet 10008 and the top of the staple cartridge 10006. The first dimension 10020 can vary with the size and shape of the staple cartridge 10006, for example, 0.0466 inches, 0.0325 inches, 0.0154 inches, or any suitable value. The second dimension 10022 is located between the bottom of the center of the magnet 10008 and the top of the hall effect sensor 10010. The second dimension may also vary with the size and shape of the staple cartridge 10006, for example, 0.0666 inches, 0.0525 inches, 0.0354 inches, 0.0347 inches, or any suitable value. The third dimension 10024 is located between the top of the processor 10012 and the leading surface 10028 of the staple cartridge 10006. The third dimension may also vary with the size and shape of the staple cartridge, for example, 0.0444 inches, 0.0440 inches, 0.0398 inches, 0.0356 inches, or any suitable value. The angle 10026 is an angle between the anvil 10002 and the top of the staple cartridge 10006. The angle 10026 can also vary with the size and shape of the staple cartridge 10006, such as, for example, 0.91 degrees, 0.68 degrees, 0.62 degrees, 0.15 degrees, or any suitable value.

Fig. 128A-128D further illustrate dimensions that can vary with the size and shape of the staple cartridge 10006 and affect the operation of the hall effect sensor 10010. Fig. 128A illustrates an exterior side view of an embodiment of the staple cartridge 10006. The staple cartridge 10006 includes ejection ears 10036. When the staple cartridge 10006 is operably coupled to the end effector 10000, as shown in fig. 126A, the ejection ear 10036 is disposed on a side of the elongate channel 10004.

Fig. 128B illustrates various possible dimensions between the lower surface 10038 of the push-out ear 10036 and the top of the hall effect sensor 10010 (not shown). The first dimension 10030a can be for a black, blue, green, or gold staple cartridge 10006, wherein the color of the body of the staple cartridge 10006 can be used to identify various aspects of the staple cartridge 10006. The first dimension 10030a can be, for example, 0.005 inches below the lower surface 10038 of the push-out ear 10036. The second dimension 10030b can be for a gray staple cartridge 10006 and can be 0.060 inches above the lower surface 10038 of the ejection ear 10036. The third dimension 10030c can be for a white staple cartridge 10006 and can be 0.030 inches above the lower surface 10038 of the ejection ear 10036.

Fig. 128C illustrates an exterior side view of an embodiment of the staple cartridge 10006. The staple cartridge 10006 includes ejection ears 10036 having a lower surface 10038. The staple cartridge 10006 also includes an upper surface 10046 that is positioned directly above the hall effect sensor 10010 (not shown). Fig. 128D illustrates various possible dimensions between the lower surface 10038 of the ejection ear 10038 and the upper surface 10046 of the staple cartridge 10006 above the hall effect sensor 10010. The first dimension 10040 can be for a black, blue, green, or gold staple cartridge 10006, and can be, for example, 0.015 inches above the lower surface 10038 of the ejection ear 10036. The second dimension 10042 can be for a gray staple cartridge 10006, and can be, for example, 0.080 inches. The third dimension 10044 may be for a white staple cartridge 10006, and may be, for example, 0.050 inches.

It should be understood that the referenced color of the body of the staple cartridge 10006 is used for convenience and exemplary purposes only. It should be understood that other cartridge 10006 body colors are possible. It should also be understood that the dimensions provided for fig. 128A-128D are also exemplary and non-limiting.

Fig. 129A illustrates various embodiments of magnets 10058a-10058d of various sizes depending on how each magnet 10058a-10058d can fit within the distal end of an anvil (e.g., the anvil 10002 illustrated in fig. 126A-126B). The magnets 10058a-10058d can be positioned in the distal tip of the anvil 10002 at a given distance 10050 from the anvil pin or pivot point 10052. It should be appreciated that this distance 10050 can vary with the configuration of the end effector and staple cartridge and/or the desired position of the magnets. Fig. 129B further illustrates a front end cross-sectional view 10054 of the anvil 10002 and a center axial point of the anvil 10002. Fig. 129A also illustrates an example 10056 of how various embodiments of magnets 10058a-10058d can be assembled within the same anvil 10002.

Fig. 130A-130E illustrate one embodiment of an end effector 10100 that includes, by way of example, magnet 10058a as shown in fig. 129A-129B. Fig. 130A shows a front end cross-sectional view of the end effector 10100. The end effector 10100 is similar to the end effector 300 described above. The end effector 10100 comprises a first jaw member or anvil 10102, a second jaw member or elongate channel 10104, and a staple cartridge 10106 operably coupled to the elongate channel 10104. The anvil 10102 further comprises a magnet 10058 a. The staple cartridge 10106 further comprises a hall effect sensor 10110. The anvil 10102 is shown here in a closed position. Fig. 130B shows a front end sectional view of the anvil 10102 and the magnet 10058a in the home position. Fig. 130C shows a perspective cutaway view of the anvil 10102 and the magnet 10058a in an optional position. Fig. 130D shows a side cross-sectional view of the anvil 10102 and the magnet 10058a in an optional position. Fig. 130E shows a top cross-sectional view of the anvil 10102 and the magnet 10058a in an optional position.

Fig. 131A-131E illustrate one embodiment of an end effector 10150 that includes, by way of example, a magnet 10058d as shown in fig. 129A-129B. Fig. 131A shows a front end cross-sectional view of the end effector 10150. The end effector 10150 includes an anvil 10152, an elongate channel 10154, and a staple cartridge 10156. The anvil 10152 further comprises a magnet 10058 d. The staple cartridge 10156 further comprises a hall effect sensor 10160. Fig. 131B shows a front end sectional view of the anvil 10150 and the magnet 10058d in situ. Fig. 131C shows a perspective cutaway view of the anvil 10152 and the magnet 10058d in an optional position. Fig. 131D shows a side cross-sectional view of the anvil 10152 and the magnet 10058D in an optional position. Fig. 131E shows a top cross-sectional view of the anvil 10152 and the magnet 10058d in an optional position.

Fig. 132 illustrates the end effector 300 as described above and illustrates the point of contact of the anvil 306 with the staple cartridge 304 and/or elongate channel 302. Contact points between the anvil 306 and the staple cartridge 304 and/or the elongate channel 302 may be used to determine the position of the anvil 306 and/or provide points for electrical contact between the anvil 306 and the staple cartridge 304 and/or between the anvil 306 and the elongate channel 302. The distal contact point 10170 may provide a contact point between the anvil 306 and the staple cartridge 304. The proximal contact point 10172 may provide a contact point between the anvil 306 and the elongate channel 302.

Fig. 133A and 133B illustrate one embodiment of an end effector 10200 that is operable to make an electrical connection with a conductive surface at a distal contact point. The end effector 10200 is similar to the end effector 300 described above. The end effector includes an anvil 10202, an elongate channel 10204, and a staple cartridge 10206. The anvil 10202 also includes a magnet 10208 and an inner surface 10210 that also includes a plurality of staple forming indentations 10212. In some embodiments, the inner surface 10210 of the anvil 10202 also includes a first conductive surface 10214 surrounding the staple forming indents 10212. First conductive surface 10214 can be in contact with second conductive surface 10222 on staple cartridge 10206, as shown in FIG. 107B. Fig. 107B illustrates a close-up view of the cartridge body 10216 of the staple cartridge 10206. The cartridge body 10216 includes staple cavities 10218 configured to retain staples (not shown). In some embodiments, the staple cavities 10218 further include staple cavity extensions 10220 that project above the surface of the cartridge body 10216. The staple cavity extension 10220 can be coated with a second conductive surface 10222. Because the staple cavity extensions 10222 project above the surface of the cartridge body 10216, the second conductive surface 10222 will be in contact with the first conductive surface 10214 when the anvil 10202 is in the closed position. In this manner, the anvil 10202 may make electrical contact with the staple cartridge 10206.

Fig. 134A-134C illustrate one embodiment showing an end effector 10250 operable to form an electrical connection with an electrically conductive surface. Fig. 134A shows an end effector 10250 including an anvil 10252, an elongate channel 10254, and a staple cartridge 10256. The anvil also includes magnets 10258 and an inner surface 10260 that also includes staple forming indentations 10262. In some embodiments, the inner surface 10260 of the anvil 10250 can further include a first conductive surface 10264 positioned, by way of example, distal to the staple forming indentations 10262, as shown in fig. 134B. The first conductive surfaces 10264 are positioned such that they contact second conductive surfaces 10272 positioned on the staple cartridge 10256, as shown in FIG. 134C. Fig. 134C illustrates the staple cartridge 10256 including the cartridge body 10266. The cartridge body 10266 also includes an upper surface 10270, which in some embodiments can be coated with a second electrically conductive surface 10272. The first conductive surfaces 10264 are positioned on the inner surface 10260 of the anvil 10252 such that they contact the second conductive surfaces 10272 when the anvil 10252 is in the closed position. As such, the anvil 10250 may make electrical contact with the staple cartridge 10256.

Fig. 135A and 135B illustrate one embodiment of an end effector 10300 that is operable to form an electrical connection with an electrically conductive surface. The end effector 10300 includes an anvil 10302, an elongate channel 10304, and a staple cartridge 10306. The anvil 10302 also includes a magnet 10308 and an inner surface 10310 that also includes a plurality of staple forming indentations 10312. In some embodiments, the inner surface 10310 further includes a first conductive surface 10314 surrounding the staple forming indentations 10312. The first conductive surface is positioned such that it is in contact with the second conductive surface 10322, as shown in fig. 109B. FIG. 109B illustrates a close-up view of the staple cartridge 10306. The staple cartridge 10306 includes a cartridge body 10316 that further includes an upper surface 10320. In some embodiments, the leading edge of the upper surface 10320 can be coated with a second conductive surface 10322. The first conductive surface 10312 is positioned such that it will contact the second conductive surface 10322 when the anvil 10302 is in the closed position. In this manner, the anvil 10302 can form an electrical connection with the staple cartridge 10306.

Fig. 136A and 136B illustrate one embodiment of an end effector 10350 that is operable to make an electrical connection with a conductive surface. Fig. 136A illustrates an end effector 10350 that includes an anvil 10352, an elongate channel 10354, and a staple cartridge 10356. The anvil 10352 also includes a magnet 10358 and an inner surface 10360 that also includes a plurality of staple forming indentations 10362. In some embodiments, the inner surface 10360 further includes a first conductive surface 10364 surrounding the staple forming indentations 10362. The first conductive surface is positioned such that it is in contact with the second conductive surface 10372, as shown in fig. 136B. Fig. 136B shows a close-up view of the staple cartridge 10356. The staple cartridge 10356 comprises a cartridge body 10366 that further comprises an upper surface 10370. In some embodiments, the leading edge of the upper surface 10327 can be coated with a second conductive surface 10372. The first conductive surface 10362 is positioned such that it will be in contact with the second conductive surface 10372 when the anvil 10352 is in the closed position. In this manner, the anvil 10352 may form an electrical connection with the staple cartridge 10356.

Fig. 137A-137C illustrate one embodiment of an end effector 10400 that is operable to make electrical connections with proximal contacts 10408. Fig. 137A illustrates an end effector 10400 that includes an anvil 10402, an elongate channel 10404, and a staple cartridge 10406. The anvil 10402 further includes a pin 10410 that extends from the anvil 10402 and allows the anvil to pivot between an open position and a closed position relative to the elongate channel 10404 and the staple cartridge 10406. Fig. 137B is a close-up view of a pin 10410 disposed within a hole 10418 defined in an elongate channel 10404 for this purpose. In some embodiments, the pin 10410 further includes a first conductive surface 10412 positioned on an exterior of the pin 10410. In some embodiments, the bore 10418 further includes a second conductive surface 10141 on an outer surface thereof. As the anvil 10402 moves between the closed and open positions, the first conductive surface 10412 on the pin 10410 rotates and contacts the second conductive surface 10414 on the surface of the hole 10418, thereby making electrical contact. Fig. 137C shows an alternative embodiment in which the second conductive surface 10416 on the surface of the hole 10418 has an alternative location.

Fig. 138 illustrates one embodiment of an end effector 10450 having a distal sensor plug 10466. End effector 10450 includes a first jaw member or anvil 10452, a second jaw member or elongate channel 10454, and a staple cartridge 10466. The staple cartridge 10466 further comprises a distal sensor plug 10466 positioned at a distal end of the staple cartridge 10466.

Fig. 139A shows the end effector 10450 with the anvil 10452 in an open position. Fig. 139B shows a cross-sectional view of the end effector 10450 with the anvil 10452 in an open position. As shown, the anvil 10452 can further comprise a magnet 10458, and the staple cartridge 10456 can further comprise a distal sensor plug 10466 and a wedge sled 10468, similar to the wedge sled 190 described above. Fig. 139C shows the end effector 10450 with the anvil 10452 in a closed position. Fig. 139D shows a cross-sectional view of the end effector 10450 with the anvil 10452 in the closed position. As shown, the anvil 10452 can further comprise a magnet 10458, and the staple cartridge 10456 can further comprise a distal sensor plug 10466 and a wedge sled 10468. As shown, the magnet 10458 is proximate to the distal sensor plug 10466 when the anvil 10452 is in a closed position relative to the staple cartridge 10456.

Fig. 140 provides a close-up view of a cross-section of the distal end of end effector 10450. As shown, the distal sensor plug 10466 may also include a hall effect sensor 10460 in communication with the processor 10462. The hall effect sensor 10460 is operatively connected to the flex board 10464. The processor 10462 is also operatively connected to the flex plate 10464 such that the flex plate 10464 provides a communication path between the hall effect sensor 10460 and the processor 10462. The anvil 10452 is shown in a closed position and as shown, the magnet 10458 is proximate the hall effect sensor 10460 when the anvil 10452 is in the closed position.

Fig. 141 illustrates a close-up top view of the staple cartridge 10456 including the distal sensor plug 10466. The staple cartridge 10456 further comprises a cartridge body 10470. The cartridge body 10470 further comprises electrical traces 10472. The electrical traces 10472 provide power to the distal sensor plug 10466 and connect to a power source at the proximal end of the staple cartridge 10456, as described in more detail below. The electrical traces 10472 can be disposed in the cartridge body 10470 by various methods, such as laser etching.

Fig. 142A and 142B illustrate one embodiment of a staple cartridge 10506 having a distal sensor plug 10516. FIG. 142A is a perspective view of the underside of the staple cartridge 10506. The staple cartridge 10506 comprises a cartridge body 10520 and a cartridge tray 10522. The staple cartridge 10506 also includes a distal sensor cover 10524 that encloses a lower region of the distal end of the staple cartridge 10506. The cartridge tray 10522 also includes electrical contacts 10526. Fig. 142B illustrates a cross-sectional view of the distal end of the staple cartridge 10506. As shown, the staple cartridge 10506 can further comprise a distal sensor plug 10516 positioned within the cartridge body 10520. The distal sensor plug 10516 also includes a hall effect sensor 10510 and a processor 10512, both of which are operatively connected to the flex plate 10514. The distal sensor plug 10516 can connect to the electrical contacts 10526, and thus can utilize the electrical conductivity in the cartridge tray 10522 as a power source. Fig. 142B also shows a distal sensor cover 10524 that encloses the distal sensor plug 10516 within the cartridge body 10520.

FIGS. 143A-143C illustrate one embodiment of a staple cartridge 10606 that includes a flexible cable 10630 connected to a Hall effect sensor 10610 and a processor 10612. Staple cartridge 10606 is similar to staple cartridge 306 described above. FIG. 143A is an exploded view of staple cartridge 10606. The staple cartridge 10606 comprises a cartridge body 10620, a wedge sled 10618, a cartridge tray 10622, and a flexible cable 10630. The flexible cable 10630 also includes electrical contacts 10632 at the proximal end of the staple cartridge 10606 that are arranged to form an electrical connection when the staple cartridge 10606 is operably coupled with an end effector (e.g., an end effector 10800 described below). The electrical contacts 10632 are integral with cable traces 10634 that extend along a portion of the length of the staple cartridge 10606. The cable trace 10634 connects 10636 near the distal end of the staple cartridge 10606, and this connection 10636 engages a conductive link 10614. Hall effect sensor 10610 and processor 10612 are operably coupled to conductive coupling 10614 such that hall effect sensor 10610 and processor 10612 can communicate.

FIG. 143B illustrates the assembly of the staple cartridge 10606 and the flexible cable 10630 in more detail. As shown, the cartridge tray 10622 encloses the underside of the cartridge body 10620, thereby enclosing the wedge sled 10618. The flexible cable 10630 can be positioned on the exterior of the cartridge tray 10622 with the conductive link 10614 positioned within the distal end of the cartridge body 10620 and the electrical contacts 10632 positioned on the exterior near the proximal end. The flexible cable 10630 may be disposed on the exterior of the cartridge tray 10622 by any suitable means, such as, for example, adhesive or laser etching.

FIG. 143C shows a cross-sectional view of the staple cartridge 10606 according to the present embodiment to illustrate the arrangement of the Hall effect sensor 10610, the processor 10612, and the conductive link 10614 within the distal end of the staple cartridge.

144A-144F illustrate one embodiment of a staple cartridge 10656 that includes a flexible cable 10680 connected to a Hall effect sensor 10660 and a processor 10662. FIG. 144A is an exploded view of staple cartridge 10656. The staple cartridge includes a cartridge body 10670, a wedge sled 10668, a cartridge tray 10672, and a flexible cable 10680. The flexible cable 10680 also includes a cable trace 10684 that extends along a portion of the length of the staple cartridge 10656. Each of the cable traces 10684 has an angle 10686 at a distal end thereof and connects therefrom to the conductive link 10664. Hall effect sensor 10660 and processor 10662 are operably coupled to conductive coupling 10664 such that hall effect sensor 10660 and processor 10662 can communicate.

FIG. 144B illustrates assembly of staple cartridge 10656. The cartridge tray 10672 encloses the underside of the cartridge body 10670, thereby enclosing the wedge sled 10668. A flexible cable 10680 is positioned between the cartridge body 10670 and the cartridge tray 10672. Thus, in this illustration, only angle 10686 and conductive coupling 10664 are visible.

FIG. 144C shows the underside of the assembled staple cartridge 10656, and also shows flexible cable 10680 in more detail. In the assembled staple cartridge 10656, conductive link 10664 is positioned in the distal end of staple cartridge 10656. Because the flexible cables 10680 can be positioned between the cartridge body 10670 and the cartridge tray 10672, only the angled 10686 ends of the cable traces 10684 and the conductive links 10664 will be visible from the underside of the staple cartridge 10656.

FIG. 144D shows a cross-sectional view of staple cartridge 10656 to illustrate the arrangement of Hall effect sensor 10660, processor 10662, and conductive link 10664. An angle 10686 of the cable trace 10684 is also shown to illustrate where the angle 10686 may be disposed. The cable traces 10684 are not shown.

FIG. 144E illustrates the underside of staple cartridge 10656 without cartridge tray 10672 and including wedge sled 10668 in its distal-most position. The staple cartridge 10656 is shown without the cartridge tray 10672 in order to illustrate the arrangement of the cable traces 10684 that might otherwise be obscured by the cartridge tray 10672. As shown, the cable traces 10684 can be placed inside the cartridge body 10670. The angle 10686 optionally allows the cable trace 10684 to occupy a narrower space in the distal end of the cartridge body 10670.

FIG. 144F also shows a staple cartridge 10656 that does not contain a cartridge tray 10672 to illustrate a possible arrangement of cable traces 10684. As shown, the cable traces 10684 can be disposed along the length of the exterior of the cartridge body 10670. In addition, the cable trace 10684 can be angled 10686 to access the interior of the distal end of the cartridge body 10670.

Fig. 145A and 145B illustrate one embodiment of a staple cartridge 10706 including a flexible cable 10730, a hall effect sensor 10710, and a processor 10712. Fig. 145A is an exploded view of the staple cartridge 10706. The staple cartridge 10706 includes a cartridge body 10720, a wedge sled 10718, a cartridge tray 10722, and a flexible cable 10730. The flexible cable 10730 also includes electrical contacts 10732 that are arranged to form an electrical connection when the staple cartridge 10706 is operably coupled with an end effector. The electrical contacts 10732 are integral with the cable traces 10734. The cable trace connects 10736 near the distal end of staple cartridge 10706, and this connection 10736 engages with conductive link 10714. Hall effect sensor 10710 and processor 10712 are operably coupled to conductive coupling 10714 such that they are capable of communication.

Fig. 145B illustrates the assembly of the staple cartridge 10706 and flexible cable 10730 in more detail. As shown, the cartridge tray 10722 encloses the underside of the cartridge body 10720, and thereby the wedge sled 10718. The flexible cable 10730 can be positioned on the exterior of the cartridge tray 10722 with the conductive link 10714 positioned within the distal end of the cartridge body 10720. The flexible cable 10730 may be placed on the exterior of the cartridge tray 10722 by any suitable means (e.g., adhesive or laser etching).

Fig. 146A-146F illustrate one embodiment of an end effector 10800 having a flexible cable 10840 operable to provide power to a staple cartridge 10806 including a distal sensor plug 10816. The end effector 10800 is similar to the end effector 300 described above. The end effector 10800 includes a first jaw member or anvil 10802, a second jaw member or elongate channel 10804, and a staple cartridge 10806 operably coupled to the elongate channel 10804. The end effector 10800 is operably coupled to the shaft assembly 10900. The axle assembly 10900 is similar to the axle assembly 200 described above. The shaft assembly 10900 also includes a closure tube 10902 that encloses the exterior of the shaft assembly 10900. In some embodiments, the shaft assembly 10900 further comprises an articulation joint 10904 that includes a double pivot closure sleeve assembly 10906. The dual pivot closure sleeve assembly 10906 includes an end effector closure sleeve assembly 10908 operable to couple with an end effector 10800.

Fig. 146A shows a perspective view of an end effector 10800 coupled to a shaft assembly 10900. In various embodiments, the shaft assembly 10900 further includes a flex cable 10830 configured to not interfere with the function of the articulation joint 10904, as described in more detail below. Fig. 146B shows a perspective view of the end effector 10800 and the underside of the shaft assembly 10900. In some embodiments, the closure tube 10902 of the shaft assembly 10900 further includes a first bore 10908 through which the flex cable 10908 can extend. The closure sleeve assembly 10908 further includes a second aperture 10910 through which the flex cable 10908 may also extend.

Fig. 146C shows the end effector 10800 with the flex cable 10830 and without the shaft assembly 10900. As shown, in some embodiments, the flexible cable 10830 can include a single coil 10832 that is operable to wrap around the articulation joint 10904 and thereby operable to flex with movement of the articulation joint 10904.

Fig. 146D and 146E show the elongate channel 10804 portion of the end effector 10800 without the anvil 10802 or staple cartridge 10806 to illustrate how the flexible cable 10830 may be disposed within the elongate channel 10804. In some embodiments, the elongate channel 10804 also includes a third aperture 10824 for receiving a flexible cable 10830. Within the body of elongate channel 10804, the flexible cable splits 10834 to form extensions 10836 located on either side of elongate channel 10804. FIG. 146E also shows that connector 10838 is operably coupled to flexible cable extension 10836.

Fig. 146F shows only the flex cable 10830. As shown, the flexible cable 10830 includes a single coil 10832 operable to wind the articulation joint 10904 and a split portion 10834 attached to the extension 10836. The extension can be coupled to a connector 10838 having prongs 10840 on a distal facing surface thereof for coupling to staple cartridge 10806, as described below.

FIG. 147 illustrates a close-up view of elongate channel 10804 having staple cartridge 10806 coupled thereto. The staple cartridge 10804 comprises a cartridge body 10822 and a cartridge tray 10820. In some embodiments, staple cartridge 10806 further includes electrical traces 10828 coupled to proximal contacts 10856 at a proximal end of staple cartridge 10806. The proximal contact 10856 may be positioned to form an electrically conductive connection with a prong 10840 of a connector 10838 coupled to the flexible cable extension 10836. Thus, when staple cartridge 10806 is operably coupled with elongate channel 10804, flexible cable 10830 may provide electrical power to staple cartridge 10806 through connector 10838 and connector pin 10840.

FIGS. 148A-148D further illustrate one embodiment of a staple cartridge 10806 that is operable with the present embodiment of an end effector 10800. FIG. 148A illustrates a close-up view of the proximal end of the staple cartridge 10806. As described above, the staple cartridge 10806 includes electrical traces 10828 that form proximal contacts 10856 at a proximal end of the staple cartridge 10806 that are operable to couple with the flexible cable 10830 as described above. FIG. 148B shows a close-up view of the distal end of staple cartridge 10806 with space for distal sensor plug 10816, as described below. As shown, electrical trace 10828 may extend along the length of staple cartridge body 10822 and form distal contact 10856 at the distal end. Fig. 148C further illustrates a distal sensor plug 10816 that, in some embodiments, is shaped to be received by a space formed therein in a distal end of staple cartridge 10806. Fig. 148D shows the proximal facing side of the distal sensor plug 10816. As shown, distal sensor plug 10816 has sensor plug contacts 10854 positioned to couple with distal contacts 10858 of staple cartridge 10806. Thus, in some embodiments, electrical trace 10828 is operable to provide power to distal sensor plug 10816.

Fig. 149A and 149B illustrate one embodiment of a distal sensor plug 10816. Fig. 149A shows a cross-sectional view of the distal sensor plug 10816. As shown, the distal sensor plug 10816 includes a hall effect sensor 10810 and a processor 10812. The distal sensor plug 10816 also includes a flex plate 10814. As further shown in fig. 149B, the hall effect sensor 10810 and the processor 10812 are operably coupled to the flex plate 10814 such that they are capable of communication.

Fig. 150 illustrates an embodiment of an end effector 10960 having a flex cable 10980 operable to provide power to sensors and electronics 10972 in the distal end of the anvil 19052 portion. The end effector 10950 includes a first jaw member or anvil 10962, a second jaw member or elongate channel 10964, and a staple cartridge 10956 operably coupled to the elongate channel 10952. The end effector 10960 is operably coupled to the shaft assembly 10960. The shaft assembly 10960 also includes a closure tube 10962 that encloses the shaft assembly 10960. In some embodiments, the shaft assembly 10960 further comprises an articulation joint 10964 that includes a double pivot closure sleeve assembly 10966.

In various embodiments, the end effector 10950 further comprises a flex cable 19080 that is configured to not interfere with the function of the articulation joint 10964. In some embodiments, the closure tube 10962 includes a first aperture 10968 through which the flex cable 10980 may extend. In some embodiments, flex cable 10980 also includes a loop or coil 10982 that wraps around the articulation joint 10964 such that the flex cable 10980 does not interfere with the operation of the articulation joint 10964, as further described below. In some embodiments, the flexible cable 10980 extends along the length of the anvil 10951 to a second hole 10970 in the distal end of the anvil 10951.

151A-151C illustrate the operation of the articulation joint 10964 and flexible cable 19080 of the end effector 10950. Fig. 151A illustrates a top view of the end effector 10952 with the end effector 109650 pivoted-45 degrees relative to the shaft assembly 10960. As shown, the coil 10982 of flex cable 10980 flexes with the articulation joint 10964 such that the flex cable 10980 does not interfere with the operation of the articulation joint 10964. Fig. 151B illustrates a top view of the end effector 10950. As shown, the coil 10982 is wrapped around the articulation joint 10964 once. Fig. 151C illustrates a top view of the end effector 10950, wherein the end effector 10950 is pivoted +45 degrees relative to the shaft assembly 10960. As shown, the coil 10982 of flex cable 10980 flexes with the articulation joint 10964 such that the flex cable 10980 does not interfere with the operation of the articulation joint 10964.

Fig. 152 shows a cross-sectional view of the distal tip of an embodiment of the anvil 10952 with sensors and electronics 10972. The anvil 10952 includes a flex cable 10980 as described with respect to fig. 150 and 151A-151C. As shown in fig. 152, the anvil 10952 further includes a second aperture 10970 through which the flexible cable 10980 can pass such that the flexible cable 10980 is within the outer housing 10974 of the anvil 10952. Within the housing 10974, the flex cable 10980 is operably coupled to the sensors and electronics 10972 positioned within the housing 10974 and thereby provides power to the sensors and electronics 10972.

Fig. 153 shows a cross-sectional view of the distal tip of the anvil 10952. Fig. 153 illustrates an embodiment of a housing 10974 that may include the sensors and electronics 10972 as shown in fig. 152.

According to various embodiments, the surgical instruments described herein may include one or more processors (e.g., microprocessors, microcontrollers) coupled to various sensors. In addition, storage (having operating logic) and a communication interface are coupled to one or more processors.

As previously described, the sensor may be configured to detect and collect data associated with the surgical device. The processor processes sensor data received from the sensors.

The processor may be configured to execute the operating logic. The processor may be any of a number of single-core or multi-core processors known in the art. The storage device may include volatile and non-volatile storage media configured to store permanent and temporary (working) copies of the operating logic.

In various embodiments, the operating logic may be configured to perform initial processing and transmit data to a computer hosting the application to determine and generate instructions. For these embodiments, the operating logic may be further configured to receive information from the hosted computer and provide feedback thereto. In alternative embodiments, the operating logic may be configured to play a more important role in receiving information and determining feedback. In either case, whether determined independently or in response to instructions from a hosted computer, the operating logic may be further configured to control and provide feedback to the user.

In various embodiments, the operating logic may be implemented by instructions supported by the Instruction Set Architecture (ISA) of the processor, or in a higher-level language, and compiled into a supported ISA. The operational logic may include one or more logical units or modules. The operational logic may be implemented in an object-oriented manner. The operating logic may be configured to be executable in a multitasking manner and/or a multithreading manner. In other embodiments, the operational logic may be implemented in hardware (such as a gate array).

In various embodiments, the communication interface may be configured to facilitate communication between the peripheral device and the computing system. The communication may include transmitting the collected biometric data associated with the position, the gesture, and/or the motion data of the user's body part to a host computer, and transmitting data associated with the haptic feedback from the host computer to the peripheral device. In various embodiments, the communication interface may be a wired or wireless communication interface. Examples of wired communication interfaces may include, but are not limited to, a Universal Serial Bus (USB) interface. Examples of wireless communication interfaces may include, but are not limited to, a bluetooth interface.

For various embodiments, a processor may be packaged with operating logic. In various implementations, a processor may be packaged with operating logic to form a SiP. In various implementations, the processor may be integrated with the operating logic on the same die. In various embodiments, a processor may be packaged with operating logic to form a system on a chip (SoC).

Various embodiments may be described herein in the general context of computer-executable instructions, such as software, program modules, and/or engines being executed by a processor. Generally, software, program modules, and/or engines include any software elements arranged to perform particular operations or implement particular abstract data types. Software, program modules, and/or engines may include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Specific implementations of software, program modules, and/or engine components and techniques may be stored on and/or transmitted across some form of computer readable media. In this regard, computer readable media can be any available media that can be used to store information and that can be accessed by a computing device. Some embodiments may also be practiced in distributed computing environments where operations are performed by one or more remote processing devices that are linked through a communications network. In a distributed computing environment, software, program modules, and/or engines may be located in both local and remote computer storage media including memory storage devices. A memory, such as a Random Access Memory (RAM) or other dynamic storage device, may be employed to store information and instructions to be executed by the processor. The memory may also be used for storing temporary variables or other intermediate information during execution of instructions to be executed by the processor.

While some embodiments may be illustrated and described as comprising functional components, software, engines, and/or modules performing various operations, it should be appreciated that such components or modules may be implemented by one or more hardware components, software components, and/or combinations thereof. The functional components, software, engines, and/or modules may be implemented by, for example, logic (e.g., instructions, data, and/or code) to be executed by a logic device (e.g., a processor). Such logic may be stored internally or externally to a logic device on one or more types of computer-readable storage media. In other embodiments, functional components such as software, engines, and/or modules may be implemented by hardware elements that may include processors, microprocessors, circuits, circuit elements (e.g., transistors, resistors, capacitors, inductors, and so forth), integrated circuits, ASICs, PLDs, DSPs, FPGAs, logic gates, registers, semiconductor device, chips, microchips, chip sets, and so forth.

Examples of software, engines, and/or modules may include software components, programs, applications, computer programs, application programs, system programs, machine programs, operating system software, middleware, firmware, software modules, routines, subroutines, functions, methods, procedures, software interfaces, Application Program Interfaces (API), instruction sets, computing code, computer code, code segments, computer code segments, words, values, symbols, or any combination thereof. Determining whether an embodiment is implemented using hardware elements and/or software elements may vary in accordance with any number of factors, such as desired computational rate, power levels, thermal tolerances, processing cycle budget, input data rates, output data rates, memory resources, data bus speeds and other design or performance constraints.

One or more of the modules described herein may include one or more embedded applications implemented as firmware, software, hardware, or any combination thereof. One or more of the modules described herein may include various executable modules such as software, programs, data, drivers, application APIs, and so forth. The firmware may be stored in the controller and/or a memory of the controller, such as a bit-mask read-only memory (ROM) or flash memory, which may include a non-volatile memory (NVM). In various implementations, storing firmware in ROM may protect flash memory. NVM may include other types of memory including, for example, programmable rom (prom), erasable programmable rom (eprom), EEPROM, or battery backed RAM (such as dynamic RAM (dram), double data rate dram (ddram), and/or synchronous dram (sdram)).

In some cases, various embodiments may be implemented as an article of manufacture. The article of manufacture may comprise a computer-readable storage medium arranged to store logic, instructions, and/or data for performing various operations of one or more embodiments. In various embodiments, the article of manufacture may comprise, for example, a magnetic disk, optical disk, flash memory, or firmware, each containing computer program instructions adapted to be executed by a general-purpose or special-purpose processor. However, the embodiments are not limited thereto.

The functions of the various functional elements, logic blocks, modules, and circuit elements described in connection with the embodiments disclosed herein may be implemented in the general context of computer-executable instructions, such as software, control modules, logic, and/or logic modules, being executed by a processing unit. Generally, software, control modules, logic, and/or logic modules include any software elements arranged to perform particular operations. Software, control modules, logic, and/or logic modules may include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Implementations of software, control modules, logic, and/or logic modules and techniques may be stored on and/or transmitted across some form of computer readable media. In this regard, computer readable media can be any available media that can be used to store information and that can be accessed by a computing device. Some embodiments may also be practiced in distributed computing environments where operations are performed by one or more remote processing devices that are linked through a communications network. In a distributed computing environment, software, control modules, logic, and/or logic modules may be located in both local and remote computer storage media including memory storage devices.

Further, it is to be understood that the embodiments described herein illustrate exemplary implementations, and that functional elements, logic blocks, modules, and circuit elements may be implemented in various other ways consistent with the described embodiments. Further, operations performed by such functional elements, logic blocks, modules, and circuit elements may be combined and/or separated for a given implementation and may be performed by a greater or lesser number of components or modules. As will be apparent to those of skill in the art upon reading this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features which may be readily separated from or combined with the features of any of the other several aspects without departing from the scope of the present disclosure. Any described method may be performed in the order of events described, or in any other logically possible order.

It is worthy to note that any reference to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase "in one embodiment" or "in one aspect" in various places in the specification are not necessarily all referring to the same embodiment.

Unless specifically stated otherwise, it may be appreciated that terms such as "processing," "computing," "calculating," "determining," or the like, refer to the action and/or processes of a computer or computing system, or similar electronic computing device, such as a general purpose processor, a DSP, an ASIC, an FPGA or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof, that is designed to perform the functions described herein, manipulate and/or transform data represented as physical quantities (e.g., electronic) within registers and/or memories into other data similarly represented as physical quantities within the memories, registers or other such information storage, transmission or display devices.

It is worthy to note that some embodiments may be described using the expression "coupled" and "connected" along with their derivatives. These terms are not intended as synonyms for each other. For example, some embodiments may be described using the terms "connected" and/or "coupled" to indicate that two or more elements are in direct physical or electrical contact with each other. However, the term "coupled" may also mean that two or more elements are not in direct contact with each other, but yet cooperate or interact with each other. In terms of software elements, for example, the term "coupled" may refer to an interface, message interface, API, exchange message, and the like.

It should be understood that any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. Likewise, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

The disclosed embodiments of the present invention have application to conventional endoscopy and open surgical instruments as well as to robotic-assisted surgery.

Embodiments of the devices disclosed herein can be designed to be disposed of after a single use, or they can be designed for multiple uses. In either or both of the above cases, the embodiments may be reconditioned for reuse after at least one use. The repair may include any combination of the following steps: disassembly of the device, followed by cleaning or replacement of particular parts and subsequent reassembly. In particular, embodiments of the device may be disassembled, and any number of the particular pieces or parts of the device may be selectively replaced or removed in any combination. Upon cleaning and/or replacement of particular components, embodiments of the device may be reassembled for subsequent use either at a reconditioning facility, or by a surgical team immediately prior to a surgical procedure. Those skilled in the art will appreciate that device reconditioning can utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. The use of these techniques and the resulting reconditioned device are all within the scope of the present application.

By way of example only, embodiments described herein may be processed prior to surgery. First, new or used instruments may be obtained and cleaned as needed. The instrument may then be sterilized. In one sterilization technique, the instrument is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and instrument may then be placed in a field of radiation that can penetrate the container, such as gamma radiation, X-rays, or high-energy electrons. The radiation may kill bacteria on the instrument and in the container. The sterilized instrument may then be stored in a sterile container. Sealing the container may maintain the instrument in a sterile state until the container is opened in a medical facility. The device may also be sterilized using any other technique known in the art, including but not limited to beta or gamma radiation, ethylene oxide, or steam.

Those skilled in the art will recognize that the components (e.g., operations), devices, objects, and their accompanying discussion described herein are for conceptual clarity purposes only and that various configuration modifications are possible. Thus, as used herein, the specific examples set forth and the accompanying discussion are intended to be representative of their more general categories. In general, the use of any particular example is intended to be representative of its class, and non-included portions of particular components (e.g., operations), devices, and objects should not be taken to be limiting.

With respect to substantially any plural and/or singular terms used herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. Various singular/plural permutations are not expressly set forth herein for the sake of clarity.

The subject matter described herein sometimes sets forth different components contained within or connected with different other components. It is to be understood that such depicted architectures are merely examples, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively "associated" such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as "associated with" each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being "operably connected," or "operably coupled," to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being "operably couplable," to each other to achieve the desired functionality. Specific examples of operably couplable include, but are not limited to, physically mateable and/or physically interacting components, and/or wirelessly interactable, and/or wirelessly interacting components, and/or logically interacting components.

Some aspects may be described using the expression "coupled" and "connected" along with their derivatives. It should be understood that these terms are not intended as synonyms for each other. For example, some aspects may be described using the term "connected" to indicate that two or more elements are in direct physical or electrical contact with each other. In another example, some aspects may be described using the term "coupled" to indicate that two or more elements are in direct physical or electrical contact. However, the term "coupled" may also mean that two or more elements are not in direct contact with each other, but yet cooperate or interact with each other.

In some instances, one or more components may be referred to herein as "configured to," "configurable to," "operable/operable," "adapted/adapted," "able," "adapted/adapted," or the like. Those skilled in the art will recognize that "configured to" may generally encompass components in an active state and/or components in an inactive state and/or components in a standby state unless the context indicates otherwise.

While particular aspects of the present subject matter described herein have been shown and described, it will be obvious to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from the subject matter described herein, and it is intended to cover in its broader aspects and, therefore, the appended claims all such changes and modifications as are within the true scope of the subject matter described herein. It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that when a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claims. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); this also applies to the use of definite articles used to introduce claim recitations.

In addition, even when a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Further, in those instances where a convention analogous to "at least one of A, B and C, etc." is used, in general such a construction is intended to have a meaning that one of ordinary skill in the art would understand the convention (e.g., "a system having at least one of A, B and C" would include, but not be limited to, systems having a alone, B alone, C, A and B together alone, a and C together, B and C together, and/or A, B and C together, etc.). In those instances where a convention analogous to "A, B or at least one of C, etc." is used, in general such a construction is intended to have a meaning that one of skill in the art would understand the convention (e.g., "a system having at least one of A, B or C" would include, but not be limited to, systems having a alone, B alone, C, A and B together alone, a and C together, B and C together, and/or A, B and C together, etc.). It will also be understood by those within the art that, in general, disjunctive words and/or phrases having two or more alternative terms, whether appearing in the detailed description, claims, or drawings, should be understood to encompass the possibility of including one of the terms, either of the terms, or both terms, unless the context indicates otherwise. For example, the phrase "a or B" will generally be understood to include the possibility of "a" or "B" or "a and B".

Those skilled in the art will appreciate from the appended claims that the operations recited therein may generally be performed in any order. In addition, while the various operational flows are listed in a certain order, it should be understood that the various operations may be performed in an order other than the order shown, or may be performed simultaneously. Unless the context dictates otherwise, examples of such alternative orderings may include overlapping, interleaved, interrupted, reordered, incremental, preliminary, supplemental, simultaneous, reverse, or other altered orderings. Furthermore, unless the context dictates otherwise, terms like "responsive," "related," or other past adjectives are generally not intended to exclude such variations.

In summary, a number of benefits resulting from employing the concepts described herein have been described. The foregoing description of one or more embodiments has been presented for purposes of illustration and description. The description is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The embodiment or embodiments were chosen and described in order to illustrate the principles and practical application of the present invention, thereby enabling one of ordinary skill in the art to utilize the present invention in various embodiments and with various modifications as are suited to the particular use contemplated. The claims as filed herewith are intended to define the full scope.

Claims (6)

1. A surgical instrument, comprising:

a first jaw;

a second jaw, wherein at least one of the first jaw and the second jaw is movable relative to the other of the first jaw and the second jaw between an open configuration and an approximated configuration to capture tissue between the first jaw and the second jaw;

a cutting member movable during a firing stroke to cut the tissue captured between the first and second jaws in the approximated configuration, the cutting member including a cutting surface at a distal portion thereof; and

a sensing module operable to measure a characteristic of the cutting surface, wherein the sensing module comprises an optical sensor defining an optical sensing region;

wherein the sensing module comprises a light source operable to emit light; and

wherein the cutting surface reflects light emitted by the light source, and wherein the optical sensor is operable to measure at least one intensity of the reflected light as the cutting surface is advanced through the optical sensing region.

2. The surgical instrument of claim 1, further comprising a cleaning mechanism.

3. The surgical instrument of claim 2, wherein the cleaning mechanism is configured to clean the cutting surface before the cutting surface enters the optical sensing region.

4. The surgical instrument of claim 1, wherein the second jaw comprises a staple cartridge comprising:

a bin body; and

a plurality of staples deployable from the cartridge body during the firing stroke, the plurality of staples being deployable into the tissue captured between the first jaw and the second jaw.

5. The surgical instrument of claim 4, wherein the sensing module comprises an optical sensor housed within the cartridge body.

6. The surgical instrument of claim 1, further comprising:

a processor; and

a memory coupled to the processor to store program instructions that, when executed from the memory, cause the processor to evaluate a sharpness of the cutting surface.

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